Corrosion-resistant coated metal and method for making the same

ABSTRACT

A corrosion-resistant coated brass metal coated with a corrosion resistant alloy. The corrosion resistant alloy is a tin metal alloy or a tin and zinc metal alloy. The corrosion resistant metal alloy may also include one or more metal additives to improve the coating process and/or to alter the properties of the tin or tin and zinc metal alloy.

[0001] This patent application is a continuation-in-part of co-pendingU.S. patent application Ser. No. 09/161,580, filed Sep. 28, 1998(FS-2199), which in turn is a continuation-in-part of U.S. patentapplication Ser. No. 08/929,623, filed Sep. 15, 1997 (FS-1779), which inturn is a continuation-in-part of U.S. Pat. No. 5,667,849, issued Sep.16, 1997 (Application Ser. No. 608,078, filed Feb. 28, 1996)(FS-9921-2), which in turn is a continuation of U.S. Pat. No. 5,616,424,issued Apr. 1, 1997 (Application Ser. No. 551,456, filed Nov. 1, 1995)(FS-9921-1), which in turn is a continuation of U.S. Pat. No. 5,491,036,issued Feb. 13, 1996 (Application Ser. No. 402,925, filed Mar. 13, 1995)(FS-9921), which in turn is a continuation-in-part of U.S. Pat. No.5,480,731, issued Jan. 2, 1996 (Application Ser. No. 380,372, filed Jan.30, 1995) (FS-8789-2), which is in turn a continuation of U.S. Pat. No.5,395,703, issued Mar. 7, 1995 (Application Ser. No. 153,026, filed Nov.17, 1993) (FS-8789-1), which in turn is a continuation of U.S. Pat. No.5,314,758,issued May 24, 1994 (Application Ser. No. 858,662, filed Mar.27, 1992) (FS-8789).

[0002] This patent application is also a continuation-in-part ofco-pending U.S. patent application Ser. No. 09/161,573, filed Sep. 28,1998 (FS-2181), which in turn is a continuation in part of U.S. patentapplication Ser. No. 08/929,623, filed Sep. 15, 1997 (FS-1779), which inturn is a continuation-in-part of U.S. Pat. No. 5,667,849, issued Sep.16, 1997 (Application Ser. No. 608,078, filed Feb. 28, 1996)(FS-9921-2), which in turn is a continuation of U.S. Pat. No. 5,616,424,issued Apr. 1, 1997 (Application Ser. No. 551,456, filed Nov. 1, 1995)(FS-9921-1), which in turn is a continuation of U.S. Pat. No. 5,491,036,issued Feb. 13, 1996 (Application Ser. No. 402,925, filed Mar. 13, 1995)(FS-9921), which in turn is a continuation-in-part of U.S. Pat. No.5,480,731, issued Jan. 2, 1996 (Application Ser. No. 380,372, filed Jan.30, 1995) (FS-8789-2), which in turn is a continuation of U.S. Pat. No.5,395,703, issued Mar. 7, 1995 (Application Ser. No. 153,026, filed Nov.17, 1993) (FS-8789-1), which in turn is a continuation of U.S. Pat. No.5,314,758, issued May 24, 1994 (Application Ser. No. 858,662, filed Mar.27,1992) (FS-8789).

[0003] This patent application is further a continuation-in-part ofco-pending U.S. patent application Ser. No. 08/929,623, filed Sep. 15,1997 (FS-1779), which in turn is a continuation-in-part of U.S. Pat. No.5,667,849, issued Sep. 16, 1997 (Application Ser. No. 608,078, filedFeb. 28, 1996) (FS-9921-2), which in turn is a continuation of U.S. Pat.No. 5,616,424, issued Apr. 1, 1997 (Application Ser. No. 551,456, filedNov. 1, 1995) (FS-9921-1), which in turn is a continuation of U.S. Pat.No. 5,491,036, issued Feb. 13, 1996 (Application Ser. No. 402,925, filedMar. 13, 1995) (FS-9921), which in turn is a continuation-in-part ofU.S. Pat. No. 5,401,586, issued Mar. 28, 1995 (Application Ser. No.175,523, filed Dec. 30, 1993) (FS-9384), which in turn is acontinuation-in-part of U.S. patent application Ser. No. 154,376, filedNov. 17, 1993 (FS-9023-1), now abandoned, which in turn is acontinuation of U.S. patent application Ser. No. 042,649, filed Apr. 5,1993 (FS-9023), now abandoned.

[0004] This patent application is still further a continuation-in-partof co-pending U.S. patent application Ser. No. 08/929,623, filed Sep.15, 1997 (FS-1779), which in turn is a continuation-in-part of U.S. Pat.No. 5,667,849, issued Sep. 16, 1997 (Application Ser. No. 608,078, filedFeb. 28, 1996) (FS-9921-2), which in turn is a continuation of U.S. Pat.No. 5,616,424, issued Apr. 1, 1997 (Application Ser. No. 551,456, filedNov. 1, 1995) (FS-9921-1), which in turn is a continuation of U.S. Pat.No. 5,491,036, issued Feb. 13, 1996 (Application Ser. No. 402,925, filedMar. 13, 1995) (FS-9921), which in turn is a continuation-in-part ofU.S. Pat. No. 5,397,652, issued Mar. 14, 1995 (Application Ser. No.165,085, filed Dec. 10, 1993) (FS-9364), which in turn is acontinuation-in-part of U.S. patent application Ser. No. 000,101, filedJan. 4, 1993 (FS-9029), now abandoned, which in turn is acontinuation-in-part of U.S. Pat. No. 5,314,758, issued May 24, 1994(Application Ser. No. 858,662, filed Mar. 27, 1992) (FS-8789).

[0005] This patent application is yet further a continuation-in-part ofco-pending U.S. patent application Ser. No. 08/929,623, filed Sep. 15,1997 (FS-1779), which in turn is a continuation-in-part of U.S. Pat. No.5,667,849, issued Sep. 16, 1997 (Application Ser. No. 608,078, filedFeb. 28, 1996) (FS-9921-2), which in turn is a continuation of U.S. Pat.No. 5,616,424, issued Apr. 1, 1997 (Application Ser. No. 551,456, filedNov. 1, 1995) (FS-9921-1), which in turn is a continuation of U.S. Pat.No. 5,491,036, issued Feb. 13, 1996 (Application Ser. No. 402,925, filedMar. 13, 1995) (FS-9921), which in turn is a continuation-in-part ofU.S. Pat. No. 5,492,772, issued Feb. 20, 1996 (Application Ser. No.394,233, filed Feb. 13, 1995) (FS-9560-1), which in turn is acontinuation-in-part of U.S. patent application Ser. No. 209,400, filedMar. 14, 1994 (FS-9487), now abandoned, which in turn is acontinuation-in-part of U.S. Pat. No. 5,401,586, issued Mar. 28, 1995(Application Ser. No. 175,523, filed Dec. 30, 1993) (FS-9384), which inturn is a continuation-in-part of U.S. patent application Ser. No.154,376, filed Nov. 17, 1993 (FS-9023-1), now abandoned, which in turnis a continuation of U.S. patent application Ser. No. 042,649, filedApr. 5, 1993 (FS-9023), now abandoned.

[0006] This patent application is still yet further acontinuation-in-part of co-pending U.S. patent application Ser. No.08/929,623, filed Sep. 15, 1997 (FS-1779), which in turn is acontinuation-in-part of U.S. Pat. No. 5,667,849, issued Sep. 16, 1997(Application Ser. No. 608,078, filed Feb. 28, 1996) (FS-9921-2), whichin turn is a continuation of U.S. Pat. No. 5,616,424, issued Apr. 1,1997 (Application Ser. No. 551,456, filed Nov. 1, 1995) (FS-9921-1),which in turn is a continuation of U.S. Pat. No. 5,491,036, issued Feb.13, 1996 (Application Ser. No. 402,925, filed Mar. 13, 1995) (FS-9921),which in turn is a continuation-in-part of U.S. Pat. No. 5,489,490,issued Feb. 6, 1996 (Application Ser. No. 341,365, filed Nov. 17, 1994)(FS-9804), which in turn is a continuation-in-part of U.S. Pat. No.5,401,586, issued Mar. 28, 1995 (Application Ser. No. 175,523, filedDec. 30, 1993) (FS-9384), which in turn is a continuation-in-part ofU.S. patent application Ser. No. 154,376, filed Nov. 17, 1993(FS-9023-1), now abandoned, which in turn is a continuation of U.S.patent application Ser. No. 042,649, filed Apr. 5, 1993 (FS-9023), nowabandoned.

[0007] This patent application is also a continuation-in-part ofco-pending U.S. patent application Ser. No. 08/929,623, filed Sep. 15,1997 (FS-1779), which in turn is a continuation-in-part of U.S. Pat. No.5,667,849, issued Sep. 16, 1997 (Application Ser. No. 608,078, filedFeb. 28, 1996) (FS-9921-2), which in turn is a continuation of U.S. Pat.No. 5,616,424, issued Apr. 1, 1997 (Application Ser. No. 551,456, filedNov. 1, 1995) (FS-9921-1), which in turn is a continuation of U.S. Pat.No. 5,491,036, issued Feb. 13, 1996 (Application Ser. No. 402,925, filedMar. 13, 1995) (FS-9921), which in turn is a continuation-in-part ofU.S. Pat. No. 5,491,035, issued Feb. 13, 1996 (Application Ser. No.347,261, filed Nov. 30, 1994) (FS-9842), which in turn is acontinuation-in-part of U.S. Pat. No. 5,401,586, issued Mar. 28,1995(Application Ser. No. 175,523, filed Dec. 30,1993) (FS-9384), which inturn is a continuation-in-part of U.S. patent application Ser. No.154,376, filed Nov. 17, 1993 (FS-9023-1), now abandoned, which in turnis a continuation of U.S. patent application Ser. No. 042,649, filedApr. 5, 1993 (FS-9023), now abandoned.

[0008] This patent application is further a continuation of co-pendingU.S. patent application Ser. No. 08/929,623, filed Sep. 15, 1997(FS-1779), which in turn is a .continuation-in-part of U.S. Pat. No.5,695,822, issued Dec. 9, 1997 (Application Ser. No. 604,078, filed Feb.20, 1996) (FS-9929-1), which in turn is a continuation of U.S. Pat. No.5,597,656, issued Jan. 28, 1997 (Application Ser. No. 438,042, filed May8, 1995) (FS-9929), which in turn is a continuation-in-part of U.S. Pat.No. 5,470,667, issued Nov. 28, 1995 (Application Ser. No. 338,386, filedNov. 14, 1994) (FS-9384-1), which in turn is a continuation of U.S. Pat.No. 5,401,586, issued Mar. 28, 1995 (Application Ser. No. 175,523, filedDec. 30, 1993) (FS-9384), which in turn is a continuation-in-part ofU.S. patent application Ser. No. 154,376, filed Nov. 17, 1993(FS-9023-1), now abandoned, which in turn is a continuation of U.S.patent application Ser. No. 042,649, filed Apr. 5, 1993 (FS-9023), nowabandoned.

[0009] This patent application is still further a continuation-in-partof co-pending U.S. patent application Ser. No. 08/980,985 filed Oct. 20,1997 (FS-1207-1), which in turn is a continuation of U.S. patentapplication Ser. No. 636,179, filed Apr. 22, 1996 (FS-1207), nowabandoned, which in turn is a continuation-in-part of U.S. Pat. No.5,616,424, issued Dec. 9, 1997 (Application Ser. No. 604,078, filed Feb.20, 1996) (FS-9929-1), which in turn is a continuation of U.S. Pat. No.5,491,036, issued Feb. 13, 1996 (Application Ser. No. 402,925, filedMar. 13, 1995) (FS-9921), which in turn is a continuation-in-part ofU.S. Pat. No. 5,480,731, issued Jan. 2, 1996 (Application Ser. No.380,372, filed Jan. 30,1995) (FS-8789-2), which is in turn acontinuation of U.S. Pat. No. 5,395,703, issued Mar. 7, 1995(Application Ser. No. 153,026, filed Nov. 17, 1993) (FS-8789-1), whichin turn is a continuation of U.S. Pat. No. 5,314,758, issued May 24,1994(Application Ser. No. 858,662, filed Mar. 27, 1992) (FS-8789).

[0010] This patent application is yet still further acontinuation-in-part of co-pending U.S. patent application Ser. No.09/071,316, filed May 1, 1998 (FS-2024), which in turn is acontinuation-in-part of co-pending U.S. patent application Ser. No.929,623, filed Sep. 15, 1997 (FS-1779), which in turn is acontinuation-in-part of U.S. Pat. No. 5,667,849, issued Sep. 16, 1997(Application Ser. No. 608,078, filed Feb. 28, 1996) (FS-9921-2), whichin turn is a continuation of U.S. Pat. No. 5,616,424, issued Apr. 1,1997 (Application Ser. No. 551,456, filed Nov. 1, 1995) (FS-9921-1),which in turn is a continuation of U.S. Pat. No. 5,491,036, issued Feb.13, 1996 (Application Ser. No. 402,925, filed Mar. 13, 1995) (FS-9921),which in turn is a continuation-in-part of U.S. Pat. No. 5,397,652,issued Mar. 14, 1995 (Application Ser. No. 165,085, filed Dec. 10, 1993)(FS-9364), which in turn is a continuation-in-part of U.S. patentapplication Ser. No. 000,101, filed Jan. 4, 1993 (FS-9029), nowabandoned, which in turn is a continuation-in-part of U.S. Pat. No.5,314,758, issued May 24, 1994 (Application Ser. No. 858,662, filed Mar.27, 1992) (FS-8789).

[0011] This patent application is also a continuation-in-part ofco-pending U.S. patent application Ser. No. 09/100,578, filed Jun. 19,1998 (FS-2136), which in turn is a continuation-in-part of co-pendingU.S. patent application Ser. No. 929,623, filed Sep. 15, 1997 (FS-1779),which in turn is a continuation-in-part of U.S. Pat. No. 5,667,849,issued Sep. 16, 1997 (Application Ser. No. 608,078, filed Feb. 28, 1996)(FS-9921-2), which in turn is a continuation of U.S. Pat. No. 5,616,424,issued Apr. 1, 1997 (Application Ser. No. 551,456, filed Nov. 1, 1995)(FS-9921-1), which in turn is a continuation of U.S. Pat. No. 5,491,036,issued Feb. 13, 1996 (Application Ser. No. 402,925, filed Mar. 13, 1995)(FS-9921), which in turn is a continuation-in-part of U.S. Pat. No.5,480,731, issued Jan. 2, 1996 (Application Ser. No. 380,372, filed Jan.30, 1995) (FS-8789-2), which is in turn a continuation of U.S. Pat. No.5,395,703, issued Mar. 7, 1995 (Application Ser. No. 153,026, filed Nov.17, 1993) (FS-8789-1), which in turn is a continuation of U.S. Pat. No.5,314,758, issued May 24, 1994 (Application Ser. No. 858,662, filed Mar.27, 1992) (FS-8789).

[0012] This patent application is also a continuation-in-part ofco-pending U.S. patent application Ser. No. 09/131,219, filed Aug. 7,1998 (FS-2143), which in turn is a continuation-in-part of co-pendingU.S. patent application Ser. No. 929,623, filed Sep. 15, 1997 (FS-1779),which in turn is a continuation-in-part of U.S. Pat. No. 5,667,849,issued Sep. 16, 1997 (Application Ser. No. 608,078, filed Feb. 28, 1996)(FS-9921-2), which in turn is a continuation of U.S. Pat. No. 5,616,424,issued Apr. 1, 1997 (Application Ser. No. 551,456, filed Nov. 1, 1995)(FS-9921-1), which in turn is a continuation of U.S. Pat. No. 5,491,036,issued Feb. 13, 1996 (Application Ser. No. 402,925, filed Mar. 13, 1995)(FS-9921), which in turn is a continuation-in-part of U.S. Pat. No.5,480,731, issued Jan. 2, 1996 (Application Ser. No. 380,372, filed Jan.30, 1995) (FS-8789-2), which is in turn a continuation of U.S. Pat. No.5,395,703, issued Mar. 7, 1995 (Application Ser. No. 153,026, filed Nov.17, 1993) (FS-8789-1), which in turn is a continuation of U.S. Pat. No.5,314,758, issued May 24, 1994 (Application Ser. No. 858,662, filed Mar.27, 1992) (FS-8789).

[0013] This patent application is also a continuation-in-part ofco-pending U.S. patent application Ser. No. 09/420,165, filed Oct. 18,1999 (FS-12592), which in turn is a continuation-in-part of U.S. Pat.No. 6,080,497, issued Jun. 27, 2000 (application Ser. No. 09/071,316,filed May 1, 1998) (FS-2043), which in turn is a continuation-in-part ofU.S. patent application Ser. No. 08/929,623, filed Sep. 15, 1997(FS-1779), which in turn is a continuation-in-part of U.S. Pat. No.5,667,849, issued Sep. 16, 1997 (Application Ser. No. 608,078, filedFeb. 28, 1996) (FS-9921-2), which in turn is a continuation of U.S. Pat.No. 5,616,424, issued Apr. 1, 1997 (Application Ser. No. 551,456, filedNov. 1, 1995) (FS-9921-1), which in turn is a continuation of U.S. Pat.No. 5,491,036, issued Feb. 13, 1996 (Application Ser. No. 402,925, filedMar. 13, 1995) (FS-9921), which in turn is a continuation-in-part ofU.S. Pat. No. 5,480,731, issued Jan. 2, 1996 (Application Ser. No.380,372, filed Jan. 30, 1995) (FS-8789-2), which is in turn acontinuation of U.S. Pat. No. 5,395,703, issued Mar. 7, 1995(Application Ser. No. 153,026, filed Nov. 17, 1993) (FS-8789-1), whichin turn is a continuation of U.S. Pat. No. 5,314,758, issued May 24,1994 (Application Ser. No. 858,662, filed Mar. 27, 1992) (FS-8789).

[0014] The present invention relates to the art of a corrosion-resistantmetal material and more particularly to a corrosion resistant alloy orcoated base metal which is coated with a corrosion resistant alloy,which alloy is environmentally friendly, and has a long life.

INCORPORATION BY REFERENCE

[0015] As background material so that the specification need not specifyin detail what is known in the art, U.S. Pat. Nos. 4,934,120; 4,982,543;4,987,716; 4,934,120; 5,001,881; 5,022,203; 5,259,166; and 5,301,474 areincorporated herein by reference to illustrate metal roofing systems ofthe type to which this invention can be used. U.S. Pat. No. 5,455,122 isincorporated herein by reference to illustrate petroleum receptacles ofthe type to which this invention can be used. U.S. Pat. No. 5,203,985 isincorporated herein by reference to illustrate a prior artelectroplating process which can be used to coat the coated base metal.U.S. Pat. Nos. 5,296,300; 5,314,758; 5,354;624; 5,395,702; 5,395,703;5,397,652; 5,401,586; 5,429,882; 5,455,122; 5,470,667; 5,480,731;5,489,490; 5,491,035; 5,491,036; 5,492,772; 5,520,964; 5,597,656;5,616,424; 5,667,849,5,695,822; and 6,080,497 and U.S. patentapplication Ser. No. 07/913,209, filed Jul. 15, 1992; Ser. No.08/042,649, filed Apr. 5, 1993; Ser. No. 08/929,623, filed Sep. 15,1997; Ser. No. 08/980,985, filed Oct. 20, 1997; Ser. No. 09/100,578,filed Jun. 19, 1998; Ser. No. 09/131,219, filed Aug. 7, 1998; Ser. No.09/161,573, filed Sep. 28,1998; Ser. No. 09/161,580, filed Sep. 28,1998; and Ser. No. 09/420,165, filed Oct. 18, 1999 are incorporatedherein by reference to illustrate various processes that can be used tocoat, treat and use the coated base metal.

BACKGROUND OF THE INVENTION

[0016] The present invention relates to the art of a corrosion-resistantmetal materials such as a corrosion-resistant metal made of acorrosion-resistant metal alloy or a base metal which is coated with acorrosion resistant metal alloy, which corrosion-resistant metalmaterial can be used in a wide variety of applications such as, but notlimited to, architectural or building materials such as roofingmaterials, siding materials, window frames, sheet metal, metal platesand the like; truck and automotive products such as, but not limited to,gasoline tanks, filter casings, body molding, body parts and the like;household products such as, but not limited to, appliance housings,electrical housings, light fixtures and the like; marine products suchas, but not limited to, boat hulls, boat masts, dock system components;and/or other types of metal materials such as, but not limited to,tools, machinery, wires, cables, electrodes, solder and the like. Theinvention also relates to various metal alloy or metal coating alloycompositions based upon metal alloys of tin and metal alloys of tin andzinc, and several novel methods and processes used therein for formingthe metal alloy materials or base metals coated with the metal alloymaterials, such as but not limited to, wire or solder forming, metalstrip forming, and coated metal forming by a plating process and/or ahot-dip process (i.e plating of metal alloy and subsequent flow heating,immersion in molten metal alloy, metal spraying of metal alloy, and/orroller coating of metal alloy), pretreatment of the base metal prior tometal alloy coating, applying an intermediate barrier metal layer priorto metal alloy coating, post-treating the metal alloy or coated basemetal, and/or forming the metal alloy or coated base metal into avariety of different articles.

[0017] Over the last several years, there has been a trend in theindustry to produce products which are higher in quality, areenvironmentally friendly, and are safe for use by humans, animals,and/or plants. This push for quality, safety and environmentalfriendliness is very apparent in the automotive industry wherein bothconsumer groups and environmental organizations are constantly lobbyingfor safer, higher-quality vehicles that are more fuel efficient and lessdetrimental to the environment. Recycling old vehicles has been oneanswer to resolving the environmental issues associated with vehicleswhich have run out their useful life. Automotive salvage markets havedeveloped for these vehicles. The vehicles are partially dismantled andsold as scrap metal wherein the metal is melted down and reformed intovarious parts. Because of the environmentally-un-friendly nature oflead, the gasoline tanks of vehicles must be removed prior to therecycling of the vehicle. Gasoline tanks are commonly made of carbon orstainless steel that are coated with a terne alloy.

[0018] Terne or terne alloy is a term commonly used to describe a metalalloy containing about 80% lead and the balance tin. The terne alloy isconventionally applied to a base metal by immersing the base metal intoa molten bath of terne metal by a continuous or batch process.

[0019] Although terne coated metals have excellent corrosion-resistantproperties and have been used in various applications, terne coatedmaterials have been questioned due to environmental concerns based onthe high lead content of the alloy. Environmental and public safety lawshave been proposed and/or passed prohibiting or penalizing the user ofmaterials containing a significant portion of lead. As a result, theseterne coated gas tanks must be disposed of in dumping yards orlandfills. Not only does the terne coated gasoline tank take up space inthe landfills, but there is a concern with the lead leaching from theterne coating into the landfill site and potentially contaminating thesurrounding area and underground water reservoirs. Plastic gasolinetanks have been used as an alternative to terne coated materials, butwith limited success. Although the use of plastic tanks eliminates theenvironmental concerns associated with lead, the plastic in-of-itself isa non-environmentally-friendly compound which does not readily degradeand therefore must be disposed of in a landfill. The plastic used tomake the gasoline tanks is usually not the type that can be recycled.Plastics have also been found to be less reliable than metal gasolinetanks with respect to durability and safety. Plastic gasoline tanks havea tendency to rupture upon impact, such as from a car accident, whereasa metal gasoline tank tends to absorb much of the shock on impact bybending and slightly deforming. Furthermore, the plastic gasoline tanksare more susceptible to being punctured from roadside debris since theplastic skin is not as strong or malleable as the skin of a metalgasoline tank. Plastic gasoline tanks also require new materials,special tools and new assembly methods to fix and install the gasolinetanks due to the nature of plastic and its physical properties. Theseadditional costs and shortcomings of plastic tanks have resulted in verylittle adoption of plastic gasoline tanks in present day motor vehicles.

[0020] The lead content in metal materials is also of some concern forbuilding materials. This is especially a concern when the metalmaterials are in contact with drinking water. In many countries leadpipe has been outlawed to reduce the amount of lead in the water. Inmany remote location throughout the world, piped water or well water isnot readily available. As a result, structures, such as portable roofsystems, are built to capture rain and to store the rain water for lateruse. These potable roof systems supply an important water source forinhabitants utilizing such structures. Roof systems that are designed tocollect rain water are typically made of metal to increase the longevityof the roofing system. Typically, the roof systems are made of carbonsteel since such metal is the least expensive. The carbon steel iscommonly coated with a terne alloy to extend the life of the roofsystem. Terne alloy is commonly used due to its relatively low cost,ease of application, excellent corrosion-resistant properties anddesirable colorization during weathering. Roof systems have been made ofother metals such as, but not limited to, stainless steel, copper,copper alloys and aluminum. Stainless steel, copper, copper alloys andaluminum were typically not coated with a terne coating since thesemetals have excellent corrosion-resistant properties. However, in somelimited applications, these metals were coated with terne to extend thelife of these metals. However, as with lead piping, there is a concernthat the lead in the terne coated roofing materials results in leaddissolving in the collected water.

[0021] Terne coated materials have typically been coated with a 6-8 lb.coating (7-11 microns), which is a very thin coating. This thin coatingcommonly includes pinholes. Terne coated materials that are drawn orformed in various types of materials such as, but not limited to,gasoline tanks, corrugated roofing materials and the like typicallyincluded one or more defects in the coating. The terne coating on thebase metal designed to protect the base metal from corroding, thuscomprising the corrosion resistance provided by the terne coating. Dueto the thin layer of the terne coating and the pinholes in the coating,the coating on the base metal, upon being drawn by a die or by beingformed tended to tear or shear the terne coating and/or elongate the pinholes on the coating thereby exposing the base metal. These exposedsurfaces were subject to corrosion and over time compromised thestructural integrity, safety and/or performance of the coated basemetal. The non-uniform coating of stainless steel metal with the ternecoating is especially evident since terne alloy does not bond as well tothe stainless steel. Another disadvantage of using a terne alloy coatingis the softness of the terne layer. The softness of the terne coating issusceptible to damage from the abrasive nature of forming machines andto environments that subject the terne coating to frequent contact withother materials.

[0022] Terne alloys have a further disadvantage in that the newlyapplied terne is very shiny and highly reflective. As a result, thehighly reflective coating cannot immediately be used in certainenvironments, such as on buildings or roofing systems in or nearairports and military establishments. The terne coating eventually losesits highly reflective properties as the components of the terne coatingare reduced (weathered); however, the desired amount of reduction takesat least approximately 1-½ to 2 years when the terne coating is exposedto the atmosphere, thus requiring the terne metals to be stored overlong periods of time prior to being used in these special areas. Thestorage time is significantly prolonged when the terne coated materialsare stored in rolls and/or the terne alloy is protected from theatmosphere.

[0023] Metallic coatings such as tin or zinc have been tested assubstitutes for terne coatings with limited success. The most popularprocess for applying a tin coating to a base metal is by anelectroplating process. In an electroplating process, the coatingthickness is very thin and typically ranges between 0.3 microns to 30microns. The very thin thicknesses of the tin coating typically resultsin a tin coating having a network of small pinholes, thereby making thecoated material generally unacceptable for use in corrosiveenvironments, such as on building materials and automotive products.Such tin plated base metals can include a flash or intermediate metallayer (plated layer) to reduce the pinhole problems inherent with thetin plating process. The tin plated layer is also susceptible to flakingor being scrapped off when the tin plated base metal is drawn through adie and/or formed into various components. The flaking of the tincoating can also cause premature clogging of filter systems and liquidlines, such as in gasoline lines and filters when tin plated basedmetals are formed into gasoline tanks. The pinholes problem, flakingand/or scraping problem that is associated with plated tin coatings isvery problematic since tin is not electroprotective under oxidizingconditions. Consequently, discontinuities in the plated tin coatingresult in the corrosion of the exposed base metal.

[0024] The plated tin coating of carbon steel is a well-known process inthe food industry. However, in the specialized art of buildingmaterials, a tin coating for base metals for use on building materialsand the like has recently been used as disclosed in U.S. Pat. No.5,314,758. Tin coatings form a highly-reflective surface. As a result,materials coated with a tin coating cannot be used in an environmentwhere highly-reflective materials are undesirable until the tin coatedmaterials are further treated (i.e. paint) or the tin is allowed time tosufficiently oxidize.

[0025] Coating a base metal with zinc metal, commonly known asgalvanizing, is another popular metal treatment to inhibit corrosion.Zinc is a desirable metal to coat materials because of its relativelylow cost, ease of application, and excellent corrosion resistance. Zincis also electroprotective under oxidizing conditions and inhibits orprevents the exposed metal, due to discontinuities in the zinc coating,from rapidly corroding. This electrolytic protection extends away fromthe zinc coating over exposed metal surfaces for a sufficient distanceto protect the exposed metal at cut edges, scratches, and other coatingdiscontinuities. Although zinc coatings bond to many types of metals,the bond is typically not very strong thereby resulting in the zinccoating flaking off the base metal over time and/or when being formed.The flaking of zinc, like the flaking of tin coatings, can causepremature clogging of filter systems and liquid lines when zinc coatedbase metal is formed into gasoline tanks. Further, when using fuelinjection systems, the small particles of zinc or zinc oxide can disablethe fuel injectors over time. Such problems are unacceptable in theautomotive field. Zinc further does not form a uniform and/or thickcoating when coating stainless steel thus resulting in discontinuitiesin the coating. Zinc is also a very rigid and brittle metal, thus tendsto crack and/or flake off when the zinc coating is formed and/or drawnthrough a die. When zinc oxidizes, the zinc coating forms a whitepowdery texture (zinc oxide). This white powdery substance isundesirable for many building applications and in various otherenvironments and applications. Consequently, the use of a tin or zinccoating as a substitute for terne coatings has not been highly reliable,or a cost effective substitute for traditional terne coatings.

[0026] Metal coatings that include tin and zinc have also been used tocoated base metals. Electroplating a tin and zinc mixture onto a steelsheet is disclosed in Japanese Patent Application No. 56-144738 filedSep. 16, 1981. The Japanese patent application discloses the plating ofa steel sheet with a tin and zinc mixture to form a coating thickness ofless than 20 microns. The Japanese patent application discloses thatafter plating, pin holes exist in the coating and subject the coating tocorrosion. The pin holes are a result of the crystalline layer of thetin and zinc mixture slowly forming during the plating process.Consequently, the Japanese patent application discloses that the platedtin and zinc coating must be covered with chromate or phosphoric acid tofill the pin holes to prevent corrosion. The Japanese patent applicationdiscloses that a preplated layer of nickel, tin or cobalt on the steelsheet surface is needed so that the plated tin and zinc mixture willadhere to the steel sheet.

[0027] The coating of steel articles by a batch hot-dip process with atin, zinc and aluminum mixture is disclosed in U.S. Pat. No. 3,962,501issued Jun. 8, 1976. The '501 patent discloses that the tin, zinc andaluminum mixture resists oxidation and maintains a metallic luster. The'501 patent also discloses that the coating is applied by a batchprocess involving the immersion of a steel article into a molten alloybath for an extended period of time. The '501 patent also discloses thata molten tin and zinc metal alloy is very susceptible to oxidationresulting in viscous oxides forming on the surface of the molten tin andzinc metal alloy. These viscous oxides cause severe problems with thecoating process. While the steel article is immersed in the moltenalloy, a large amount of dross forms on the surface of the molten alloy.The dross results in non-uniformity of the coating and the formation ofpin holes as the steel article is removed from the molten metal. The'501 patent discloses that the addition of up to 25% aluminum to the tinand zinc metal alloy inhibits dross formation, prevents Zn—Fe alloyformation, and reduces viscous oxide formation on the molten bathsurface. The batch process disclosed in the '501 patent subjects thesurface of the article to differing residence times in the molten alloywhich can result in differing coating thicknesses and coating propertieson the coated article.

[0028] The treatment of a steel sheet by plating tin and zinc followedby heat flowing is disclosed in U.S. Pat. No. 4,999,258. The '258 patentdiscloses a steel sheet plated with a layer of tin and a subsequentlayer of zinc. The tin and zinc plated layers are then heated until thezinc alloys with the tin. The tin is applied at 0.2-1.0 g/m² and thezinc is applied at 0.01-0.3 g/m². The '258 patent also discloses thatwhen less than 1% zinc is used, the beneficial effect of the zinc isnull; however, when more than 30% zinc is used, the coating will rapidlycorrode under adverse environments. The '258 patent also discloses thata nickel plated layer is preferably applied to the steel sheet prior toapplying the tin and zinc plated layers to improve corrosion resistance.The heat treated tin and zinc layer can be further treated by applying achromate treatment to the plated layer further improve corrosionresistance.

[0029] A continuous process for electroplating a carbon steel strip isdisclosed in U.S. Pat. No. 5,203,985. The '985 patent discloses thatnickel is electroplated on a continuously moving strip of carbon steel.After the carbon steel has been nickel plated, the plated strip is hotdip coated with molten zinc.

[0030] The electroplating of tin, tin-nickel or tin and zinc by anelectroplating process and subsequent formation of an intermetalliclayer by heat flowing the plated layer is disclosed in U.S. Pat. No.5,433,839.

[0031] Due to the various environmental concerns and problems associatedwith corrosion-resistant coatings applied to base metals and theproblems associated with the inadvertent removal of thecorrosion-resistant coating during the forming and/or drawing of thecoated materials, there has been a demand for a coating or metalmaterial that is corrosion-resistant, is environmentally friendly, andresists damage during forming into end components. Many of these demandswhere met by the tin metal alloy or the tin and zinc metal alloy andprocess and method for applying these alloys to a base metal which isdisclosed in Applicants U.S. Pat. Nos. 5,314,758; 5,354,624; 5,395,702;5,395,703; 5,397,652; 5,401,586; 5,429,882; 5,455,122; 5,470,667;5,480,731; 5,489,490; 5,491,035; 5,491,036; 5,492,772; 5,520,964;5,597,656; 5,616,424; 5,667,849. The present invention is an improvementor refinement of the alloys and/or use of the alloys disclosed in theseprior patents.

SUMMARY OF THE INVENTION

[0032] The present invention relates to a product and method ofproducing a corrosion-resistant, environmentally friendly metalmaterial. More particularly, the invention relates to a metal materialthat is at least partially composed of a corrosion resistant metalalloy, or the coating of a base metal with a corrosion resistant metalalloy which forms a corrosive-resistant barrier on the base metal. Evenmore particularly, the invention relates to a corrosion resistant metalalloy or a base metal coated with a corrosion-resistant metal alloywhich corrosion resistant metal alloy or coated base metal is formedinto truck and automotive products, architectural or building materials,household materials, marine products; and/or formed into tools,machinery, cable, wire, wire solder or welding electrodes.

[0033] In accordance with the principal feature of the invention, thereis provided a corrosion resistant metal alloy primarily including tin ortin and zinc. In one embodiment of the invention, the corrosionresistant metal alloy is formed, molded and/or drawn into a metalarticle. In another embodiment of the invention, the corrosion resistantmetal alloy is coated on a base metal, which coated base metal isformed, molded, and/or drawn into a metal article.

[0034] In accordance with one aspect of the invention, a metal alloythat primarily includes tin and zinc is a tin and zinc metal alloy. Thetin and zinc metal alloy is a composite alloy wherein the tin and zincconstituents maintain their own integrity (structure or composition) inthe composite with one phase metal being a matrix surrounding distinctglobules or phases of the second phase metal. The tin and zinc system isa dual strata of metal globules or phases, each globule or phase beingdistinct from the other in structure or composition. The lowest weightpercentage of zinc in an eutectic tin and zinc mixture is a tin richmixture containing about 90-91 weight percent tin and about 9-10 weightpercent zinc. For the tin rich matrix or phase and zinc rich globules orphases to form in a tin and zinc metal alloy, the zinc must make up atleast over about 9-10 weight percent of the tin and zinc metal alloy. Azinc content over about 9-10 weight percent of the tin and zinc alloyresults in the zinc precipitating out of the tin and forming zincglobules or phases within the tin and zinc metal alloy. The tin contentof the tin and zinc metal alloy must be at least about 15 weight percentof the tin and zinc metal alloy so that there is a sufficient amount oftin within the tin and zinc metal alloy to form the tin phase about thezinc phase. A metal alloy that primarily includes tin and zinc but has azinc content that is equal to or less than the minimum eutectic weightpercentage of zinc is not a tin and zinc metal alloy. As defined herein,a tin and zinc alloy is a metal alloy that includes at least about 15weight percent tin and at least about 10 weight percent zinc and the tincontent plus zinc content of the metal alloy constitutes at least amajority of the metal alloy. One of the important and desirableproperties of the tin and zinc metal alloy is its excellentcorrosion-resistance in many different environments. The tin and zincmetal alloy is very corrosion resistant in marine environments whereinchloride salts are common, and in industrial environments wherein sulfurand sulfur compounds are present. The excellent corrosion-resistance ofthe tin and zinc metal alloy is believed to result from the formation ofa stable, continuous, adherent, protective film on the surface. Thedamaged film generally reheals itself quickly. Because of the generalinertness of the film, that is at least partially formed of tin and zincoxide, in most atmospheres, the corrosion resistant tin and zinc metalalloy is considered to be environmentally safe and friendly, andconsidered a safe material to be used in the human environment. The tinand zinc metal alloy also forms a dull, low-reflecting surface; has apleasing color; performs well in low temperatures; has a relatively lowcoefficient of thermal expansion; resists degradation by solar energy;can be molded, cast, formed, drawn, soldered, painted and/or colored;and/or can be installed in a variety of weather conditions. The tin andzinc metal alloy is further a cost effective material for use instructures used in corrosive environments such as in the tropics andother areas where buildings are exposed to strong winds, corrosivefumes, and/or marine conditions. The tin and zinc metal alloy can alsobe used as a solder and/or wire electrode. In one embodiment of theinvention, the tin content plus the zinc content in the tin and zincmetal alloy makes up over 50 weight percent of the tin and zinc metalalloy. In one aspect of this embodiment, the tin content plus the zinccontent in the tin and zinc metal alloy is at least about 60 weightpercent of the tin and zinc metal alloy. In another aspect of thisembodiment, the tin content plus the zinc content in the tin and zincmetal alloy is at least about 75 weight percent of the tin and zincmetal alloy. In yet another aspect of this embodiment, the tin contentplus the zinc content in the tin and zinc metal alloy is at least about80 weight percent of the tin and zinc metal alloy. In still yet anotheraspect of this embodiment, the tin content plus the zinc content in thetin and zinc metal alloy is at least about 85 weight percent of the tinand zinc metal alloy. In a further aspect of this embodiment, the tincontent plus the zinc content in the tin and zinc metal alloy is atleast about 90 weight percent of the tin and zinc metal alloy. In yet afurther aspect of this embodiment, the tin content plus the zinc contentin the tin and zinc metal alloy is at least about 95 weight percent ofthe tin and zinc metal alloy. In still a further aspect of thisembodiment, the tin content plus the zinc content in the tin and zincmetal alloy is at least about 98 weight percent of the tin and zincmetal alloy. In still yet a further aspect of the embodiment, the tinplus zinc content in the tin and zinc metal alloy is at least about 99weight percent of the tin and zinc metal alloy.

[0035] In accordance with another aspect of the invention, a metal alloythat primarily includes tin and equal to or less than the minimumeutectic weight percentage of zinc, when zinc is included in the metalalloy, is a tin metal alloy. As defined herein, a tin metal alloy is ametal alloy that includes at least a majority of the metal alloy andincludes less than 10 weight percent zinc, when zinc is included in themetal alloy. The corrosion resistant tin metal alloy forms a corrosionresistant coating that protects the surface of the base metal fromoxidation. The corrosion resistant tin metal alloy provides protectionto the base metal in a variety of environments such as rural,industrial, and marine environments. The corrosion resistant tin metalalloy also performs well in low temperatures; has a relatively lowcoefficient of thermal expansion; has a pleasing color; resistsdegradation by solar energy; can be molded, cast, formed, drawn,soldered, painted and/or colored; and/or can be installed in a varietyof weather conditions. Because of the relative inertness of the tinoxide in many environments, the corrosion resistant tin metal alloy isconsidered to be environmentally safe and friendly and considered a safematerial to be used in the human environment. The corrosion resistanttin metal alloy is also a cost effective material for use in structureserected in corrosive environments, such as in the tropics and otherareas where buildings are exposed to strong winds, corrosive fumes,and/or marine conditions. The tin metal alloy can be used as a solderand/or wire electrode. In one embodiment of the invention, the tincontent in the tin metal alloy makes up over 50 weight percent of thetin metal alloy. In one aspect of this embodiment, the tin content inthe tin metal alloy is at least about 75 weight percent of the tin metalalloy. In another aspect of this embodiment, the tin content in the tinmetal alloy is at least about 80 weight percent of the tin metal alloy.In yet another aspect of this embodiment, the tin content in the tinmetal alloy is at least about 85 weight percent of the tin metal alloy.In still yet another aspect of this embodiment, the tin content in thetin metal alloy is at least about 90 weight percent of the tin metalalloy. In a further aspect of this embodiment, the tin content in thetin metal alloy is at least about 95 weight percent of the tin metalalloy. In yet a further aspect of this embodiment, the tin content inthe tin metal alloy is at least about 98 weight percent of the tin metalalloy. In still a further aspect of this embodiment, the tin content inthe tin metal alloy is at least about 99 weight percent of the tin metalalloy.

[0036] In accordance with yet another aspect of the invention, thecorrosion resistant tin metal alloy and corrosion resistant tin and zincmetal alloy contain a low lead content. The lead source in the tin metalalloy or the tin and zinc metal alloy can be from impurities in the rawtin and/or zinc ore used to make the metal alloy, and/or can be fromdirected additions of lead to the metal alloy. In some metal alloycombinations, lead in the metal alloy positively affects one or morephysical and/or chemical properties of the metal alloy. Metal alloysthat include little or no lead are considered more environmentallyfriendly, and the prejudices associated with high lead containing alloysare overcome. In one embodiment of the invention, the tin metal alloyand the tin and zinc metal alloy includes no more than about 10 weightpercent lead. In one aspect of this embodiment, the metal alloy includesless than about 2 weight percent lead. In another aspect of thisembodiment, the metal alloy includes less than about 1 weight percentlead. In yet another aspect of this embodiment, the tin metal alloy andthe tin and zinc metal alloy includes less than about 0.5 weight percentlead. In still another aspect of this embodiment, the metal alloyincludes less than about 0.05 weight percent lead. In still yet anotheraspect of this embodiment, the metal alloy includes less than about 0.01weight percent lead.

[0037] In accordance with a further aspect of the invention, the tinmetal alloy and tin and zinc metal alloy include one or more additives.In one embodiment of the invention, the one or more additives generallyconstitute less than about 25 weight percent of the metal alloy. In oneaspect of this embodiment, the one or more additives constitute lessthan about 10 weight percent of the metal alloy. In another aspect ofthis embodiment, the one or more additives constitute less than about 5weight percent of the metal alloy. In yet another aspect of thisembodiment, the one or more additives constitute less than about 2weight percent of the metal alloy. In still another aspect of thisembodiment, the one or more additives constitute less than about 1weight percent of the metal alloy. In still yet another aspect of thisembodiment, the one or more additives constitute less than about 0.5weight percent of the metal alloy. In another embodiment of theinvention, the additives include, but are not limited to, aluminum,antimony, arsenic, bismuth, boron, bromine, cadmium, carbon, chlorine,chromium, copper, cyanide, fluoride, iron, lead, magnesium, manganese,molybdenum, nickel, nitrogen, phosphorous, potassium, silicon, silver,sulfur, tellurium, titanium, vanadium, and/or zinc. The one or moreadditives included in the corrosion resistant metal alloy are used toenhance the mechanical properties of the alloy, to improve corrosionresistance of the metal alloy, to improve grain refinement of the metalalloy, to alter the color of the metal alloy, to alter thereflectiveness of the metal alloy, to inhibit oxidation of the metalalloy during forming or coating of the metal alloy and/or when the metalalloy is exposed in various types of environments, to inhibit drossformation during the forming or coating of the metal alloy, to stabilizeone or more components of the metal alloy, to improve the bonding of themetal alloy on the base metal and/or intermediate barrier metal layer onthe base metal, to improve the flowability of the metal alloy during theforming or coating process, to produce the thickness of heat createdintermetallic layer, and/or to reduce or inhibit the crystallization ofthe tin in the metal alloy. The inclusion of one or more additives inthe corrosion resistant metal alloy preforms one or more of the abovelisted functions and/or features in the metal alloy. The believedfunctions and features of select additives are described below; however,the described additives may have additional functions and features.Aluminum reduces the rate of oxidation of the molten metal alloy;reduces dross formation during the coating process; alters thereflective properties of the metal alloy; alters the mechanicalproperties of the metal alloy (i.e. coatability, durability,flexibility, flowability, formability, hardness, and strength); and/orreduces the thickness of the heat created intermetallic layer to improvethe formability of the coated base metal. Antimony, bismuth, cadmium,and/or copper prevents or inhibits the crystallization of the tin in themetal alloy, which crystallization can weaken the bonding and/or resultin flaking of the corrosion resistant metal alloy; improves the bondingproperties of the metal alloy to the base metal and/or intermediatebarrier metal layer; alter the mechanical properties of the metal alloy;and/or alters the corrosion resistant properties of the metal alloy.Only small amounts of antimony, bismuth, cadmium, and/or copper areneeded to prevent and/or inhibit the crystallization of the tin. Thissmall amount can be as low as about 0.001-0.05 weight percent, andtypically as low as 0.001-0.004 weight percent. Arsenic alters themechanical properties of the metal alloy. Cadmium, in addition to itsbonding, corrosion resistant, stabilizing and/or mechanical alteringproperties, reduces the rate of oxidation of the molten metal alloy;reduces dross formation during the coating or forming process of themetal alloy; alters the color and/or reflective properties of the metalalloy; and/or improves the grain refinement of the metal alloy. Chromiumprovides additional corrosion protection to the metal alloy; alters themechanical properties of the metal alloy; and/or alters the color and/orreflective properties of the metal alloy. Copper, in addition to itscorrosion resistant, stabilizing and/or mechanical altering properties,alters the color and/or reflective properties of the metal alloy. Ironalters the mechanical properties of the metal alloy; and/or alters thecolor of the metal alloy. Lead provides additional corrosion protectionto the metal alloy; alters the mechanical properties of the metal alloy;alters the color of the metal alloy; and/or improves the bondingproperties of the metal alloy to the base metal and/or intermediatebarrier metal layer. Magnesium alters the mechanical properties of themetal alloy; reduces the anodic characteristics of the metal alloy;reduces the rate of oxidation of the molten metal alloy; and/or reducesdross formation during the forming or coating process of the metalalloy. Manganese provides additional corrosion protection to the metalalloy; improves the grain refinement of the metal alloy; and/or improvesthe bonding properties of the metal alloy to the base metal and/orintermediate barrier metal layer. Nickel provides corrosion protectionto the metal alloy, especially in alcohol and chlorine containingenvironments; alters the mechanical properties of the metal alloy;and/or alters the color and/or reflective properties of the metal alloySilver alters the mechanical properties of the metal alloy; and/oralters the color and/or reflective properties of the metal alloy.Titanium improves the grain refinement of the metal alloy; alters themechanical properties of the metal alloy; provides additional corrosionprotection to the metal alloy; reduces the rate of oxidation of themolten metal alloy; reduces dross formation during the forming orcoating process of the metal alloy; alters the color and/or reflectiveproperties of the metal alloy; and/or improves the bonding properties ofthe metal alloy to the base metal and/or intermediate barrier metallayer. Zinc alters the mechanical properties of the metal alloy;provides additional corrosion protection to the metal alloy, alters thecolor and/or reflective properties of the metal alloy; improves thebonding properties of the metal alloy to the base metal and/orintermediate barrier metal layer, and/or stabilizes the tin to inhibitor prevent crystallization of the tin in the metal alloy.

[0038] In accordance with another aspect of the invention, the thicknessof the corrosion resistant metal alloy is selected to provide thedesired amount of corrosion resistant protection to the surface of thebase metal. Generally thinner coating thicknesses can be obtained by aplating process and thicker coating thicknesses can be obtained byimmersion in molten metal alloy. The selected thickness of the coatingwill typically depend on the use of the coated base metal and theenvironment the coated base metal is to be used. A 6 lb. coating on abase metal is a common thickness for a thin coating. A 6 lb. coating hasa coating thickness of about 7 microns. A 6 lb. coating is commonlyapplied by a plating process. In many instances, very thin coatingthickness includes one or more pin holes in the coating. A 40 lb.coating on a base metal is also a common coating having a thickness ofabout 50 microns. A 40 lb. coating typically has few, if any, pin holes,and due to the thicker coating, resists tearing when the coated metalstrip is drawn or formed into various types of components. Thicker metalalloy coatings are commonly used for automotive components (i.e.gasoline tank shell members), and roofing and siding materials. In oneembodiment of the invention, the metal alloy coating is applied by asingle plating process. In one aspect of this embodiment, the thicknessof the metal alloy coating is at least about 1 micron. In another aspectof this embodiment, the thickness of the metal alloy coating is at leastabout 2 microns. In still another aspect of this embodiment, thethickness of the metal alloy coating is about 2-30 microns. In anotherembodiment of the invention, the metal alloy coating is applied by a)multiple plating processes, b) single or multiple hot-dip processes,and/or c) at least one plating process and at least one hot dip process.In one aspect of this embodiment, the thickness of the metal alloycoating is at least about 1 micron. In another aspect of thisembodiment, the thickness of the metal alloy coating is up to about2550. In still another aspect of this embodiment, the thickness of themetal alloy coating is about 2.5-1270 microns. In yet another aspect ofthis embodiment, the thickness of the metal alloy coating is about7-1270 microns. In still yet another aspect of this embodiment, thethickness of the metal alloy coating is about 7-1250 microns. In afurther aspect of this embodiment, the thickness of the metal alloycoating is about 15 to 1250 microns. In yet a further aspect of thisembodiment, the thickness of the metal alloy coating is about 25-77microns. In still a further aspect of this embodiment, the thickness ofthe metal alloy coating is about 25-51 microns.

[0039] In accordance with still another aspect of the invention, thebase metal is a metal strip. A “strip” is defined as metal in the formof a thin metal sheet that is or can be rolled into a roll of metal, asopposed to plates of metal or other configurations of the metal. Metalstrip which has a thickness of less than about 127 microns (0.005 inch)can break as the strip is pretreated and/or coated with a metal alloycoating at high process speeds. A high process speed is defined as ametal strip moving through the pretreatment process, intermediatebarrier metal coating process and/or metal alloy coating process at aspeed of about 60-400 ft/min. However, the metal strip thickness shouldnot be too great so as to prevent the strip from being able to bedirected, at a relatively high speed, through the pretreatment process,if any, and the coating process. Metal strip which is too thick is moredifficult to heat when a heat created intermetallic layer is to formedbetween the base metal and metal alloy coating and/or intermediatebarrier metal, especially when the metal strip is moving at high speedsand/or coated over a short period of time. Metal strips having too greatof thickness are also difficult to maneuver at economical high speedsthrough the pretreatment process, if any, and the coating process. Inone embodiment of the invention, the thickness of the metal strip isthin enough such that the metal strip can be unrolled from a roll ofmetal, coated by a metal alloy coating, and re-rolled into a roll ofcoated metal stip. In one aspect of this embodiment, the thickness ofthe metal strip is not more than about 5080 microns. In another aspectof this embodiment, the thickness of the metal strip is less than about2540 microns. In yet another aspect of this embodiment, the thickness ofthe metal strip is less than about 1270 microns. In still another aspectof this embodiment, the thickness of the metal strip is less than about762 microns. In a further aspect of this embodiment, the thickness ofthe metal strip is about 127-762 microns. In yet a further aspect ofthis embodiment, the thickness of the metal strip is about 254-762microns. In still a further aspect of this embodiment, the thickness ofthe metal strip is about 381-762 microns. In yet a further aspect ofthis embodiment, the thickness of the metal strap is about 127-381microns. In still yet a further aspect of this embodiment, the thicknessof the metal strip is about 508-762 microns. In another embodiment ofthe invention, the thickness of the metal strip is not more than about1588 microns when the metal strip is formed of stainless steel, carbonsteel, nickel alloys, titanium or titanium alloys. These types of metalstrip are difficult to maneuver at economical, high speeds through thecoating process when the metal strip thickness is greater than 1588microns. In one aspect of this embodiment, metal strip made of stainlesssteel, carbon steel, nickel alloys, titanium or titanium alloy strip hasa thickness of about 255-762 microns.

[0040] In accordance with still yet another aspect of the invention, thebase metal is a metal plate. In one embodiment of the invention, themetal plate is a rectangular or square metal plate having a length ofabout 1 to 15 feet and a width of about 1-20 feet. In another embodimentof the invention, the thickness of the metal plate is not more thanabout 51000 microns (2 inches). In one aspect of this embodiment, thethickness of the metal plate is not more than about 25400 microns. Inanother aspect of this embodiment, the thickness of the metal plate isnot more than about 12700 microns. In still another aspect of thisembodiment, the thickness of the metal plate is not more than about 1270microns. In yet another aspect of this embodiment, the thickness of themetal plate is about 127-5080 microns. In still yet another aspect ofthis embodiment, the thickness of the metal plate is about 127-1270microns. In a further aspect of this embodiment, the thickness of themetal plate is about 127-381 microns.

[0041] In accordance with another aspect of the invention, the basemetal is carbon steel. In one embodiment of the invention, the carbonsteel base metal is a metal strip. In one aspect of this embodiment, thethickness of the carbon steel strip is less than about 2540 microns. Inanother aspect of this embodiment, the thickness of the carbon steelstrip is less than about 1588 microns. In yet another aspect of thisembodiment, the thickness of the carbon steel strip is less than about1270 microns. In still another aspect of this embodiment, the thicknessof the carbon steel strip is up to about 762 microns. In a furtheraspect of this embodiment, the thickness of the carbon steel strip isabout 127-762 microns. In yet a further aspect of this embodiment, thethickness of the carbon steel strip is about 254-762 microns. In still afurther aspect of this embodiment, the thickness of the carbon steelstrip is about 381-762 microns. In another embodiment of the invention,the carbon steel base metal is a metal plate.

[0042] In accordance with still another aspect of the invention, thebase metal is stainless steel. “Stainless steel” is used in itstechnical sense and includes a large variety of ferrous alloyscontaining chromium and iron. Carbon steel base metal that is platedwith chromium and subsequently coated with a metal alloy coating by ahot dip process transforms the carbon steel into stainless steel atleast at the surface of the base metal surface. The stainless steel mayalso contain other elements or compounds such as, but not limited to,nickel, nickel alloys, carbon, molybdenum, silicon, manganese, titanium,boron, copper, aluminum and various other metals or compounds. Elementssuch as nickel can be flashed (plated) onto the surface of the stainlesssteel or directly incorporated into the stainless steel. In oneembodiment of the invention, the stainless steel base metal is 304 or316 stainless steel. In another embodiment of the invention, thestainless steel base metal is a metal strip. In one aspect of thisembodiment, the thickness of the stainless steel strip is less thanabout 2540 microns. In another aspect of this embodiment, the thicknessof the stainless steel strip is less than about 1588 microns. In yetanother aspect of this embodiment, the thickness of the stainless steelstrip is less than about 1270 microns. In still another aspect of thisembodiment, the thickness of the stainless steel strip is up to about762 microns. In a further aspect of this embodiment, the thickness ofthe stainless steel strip is about 127-762 microns. In yet a furtheraspect of this embodiment, the thickness of the stainless steel strip isabout 254-762 microns. In still a further aspect of this embodiment, thethickness of the stainless steel strip is about 381-762 microns. Instill another embodiment of the invention, the stainless steel basemetal is a metal plate.

[0043] In accordance with yet another aspect of the invention, the basemetal is copper. Copper metal is known for its malleability propertiesand natural corrosion resistant properties. Copper metal that is coatedwith a metal alloy can be formed in a variety of simple and complexshapes. In one embodiment of the invention, the copper base metal is ametal strip. In one aspect of this embodiment, the thickness of thecopper strip is not more than about 5080 microns. In another aspect ofthis embodiment, the thickness of the copper strip is less than about2540 microns. In yet another aspect of this embodiment, the thickness ofthe copper strip is less than about 1270 microns. In still anotheraspect of this embodiment, the thickness of the copper strip is up toabout 762 microns. In a further aspect of this embodiment, the thicknessof the copper strip is about 127-762 microns. In yet a further aspect ofthis embodiment, the thickness of the copper strip is about 254-762microns. In still a further aspect of this embodiment, the thickness ofthe copper strip is about 381-762 microns. In still another embodimentof the invention, the copper base metal is a metal plate.

[0044] In accordance with still yet another aspect of the invention, thebase metal is a copper alloy. “Copper alloys” as used herein include,but are not limited to, brass and bronze. Brass is defined as a copperalloy that includes a majority of copper and zinc. Bronze is defined asan alloy that includes tin and a majority of copper. Brass and bronzeare copper alloys with known corrosion resistant properties in variousenvironments. Although brass and bronze are relatively corrosionresistant in many environments, brass and bronze are susceptible to agreater degree of corrosion in some environments than others. Brass andbronze are also relatively bright and reflective materials which can beundesirable for use in several applications. As a result, it has beenfound that brass and bronze coated with a corrosion resistant metalalloy can overcomes these deficiencies. In one embodiment of theinvention, the copper content of the brass is about 50.1-99 weightpercent and the zinc content is about 1-49.9 weight percent. In oneaspect of this embodiment, the brass includes one or more additives suchas, but not limited to, aluminum, beryllium, carbon, chromium, cobalt,iron, lead, manganese, magnesium, nickel, niobium, phosphorous, silicon,silver, sulfur, and/or tin. These additives typically alter themechanical and/or corrosion resistant properties of the brass. Inanother embodiment of the invention, the bronze includes one or moreadditives such as, but not limited to, aluminum, iron, lead, manganese,nickel, nitrogen, phosphorous, silicon, and/or zinc. In still anotherembodiment of the invention, the copper alloy base metal is a metalstrip. In one aspect of this embodiment, the thickness of the copperalloy strip is not more than about 5080 microns. In another aspect ofthis embodiment, the thickness of the copper alloy strip is less thanabout 2540 microns. In yet another aspect of this embodiment, thethickness of the copper alloy strip is less than about 1270 microns. Instill another aspect of this embodiment, the thickness of the copperalloy strip is less than about 762 microns. In a further aspect of thisembodiment, the thickness of the copper alloy strip is about 127-762microns. In yet a further aspect of this embodiment, the thickness ofthe copper alloy strip is about 254-762 microns. In still a furtheraspect of this embodiment, the thickness of the copper alloy strip isabout 381-762 microns. In yet another embodiment of the invention, thecopper alloy base metal is a metal plate.

[0045] In accordance with a further aspect of the invention, the basemetal is made of aluminum, aluminum alloys, nickel alloys, tin,titanium, or titanium alloys. “Aluminum alloys” are used herein include,but are not limited to, alloys including at least about 10 weightpercent aluminum. “Nickel alloys” are used herein include, but are notlimited to, alloys including at least about 5 weight percent nickel. Inone embodiment of the invention, the base metal is an aluminum metalstrip. In another embodiment of the invention, the base metal is aaluminum alloy metal strip. In yet another embodiment of the invention,the base metal is a nickel alloys, tin, titanium, or titanium alloysstrip. In still another embodiment of the invention, the base metal is atin metal strip. In still yet another embodiment of the invention, thebase metal is a titanium metal strip. In a further embodiment of theinvention, the base metal is a titanium alloy metal strip. In one aspectof these embodiments, the thickness of the aluminum, aluminum alloys,nickel alloys, tin, titanium, or titanium alloys strip is less thanabout 2540 microns. In another aspect of these embodiments, thethickness of the aluminum, aluminum alloys, nickel alloys, tin,titanium, or titanium alloys strip is less than about 1588 microns. Inyet another aspect of these embodiments, the thickness of the aluminum,aluminum alloys, nickel alloys, tin, titanium, or titanium alloys stripis less than about 1270 microns. In still another aspect of theseembodiments, the thickness of the aluminum, aluminum alloys, nickelalloys, tin, titanium, or titanium alloys strip is up to about 762microns. In a further aspect of these embodiments, the thickness of thealuminum, aluminum alloys, nickel alloys, tin, titanium, or titaniumalloys strip is about 127-762 microns. In yet a further aspect of theseembodiments, the thickness of the aluminum, aluminum alloys, nickelalloys, tin, titanium, or titanium alloys strip is about 240-762microns. In still a further aspect of these embodiments, the thicknessof the aluminum, aluminum alloys, nickel alloys, tin, titanium, ortitanium alloys strip is about 381-762 microns. In yet a furtherembodiment of the invention, the base metal is an aluminum metal plate.In still a further embodiment of the invention, the base metal is aaluminum alloy metal plate. In still yet a further embodiment of theinvention, the base metal is a nickel alloy plate. In another embodimentof the invention, the base metal is a tin metal plate. In yet anotherembodiment of the invention, the base metal is a titanium metal plate.In still another embodiment of the invention, the base metal is atitanium alloy metal plate.

[0046] In accordance with a yet further aspect of the invention, thebase metal is pretreated prior to applying the metal alloy to the basemetal. The pretreatment of the base metal is designed to remove dirt,oil, adhesives, plastic, paper and other foreign substances from thesurface of the base metal; to remove oxides and other compounds from thebase metal surface; etch the base metal surface; and/or improve thebonding of the metal alloy coating to the surface of the base metal. Thepretreatment process may include one or more process steps depending onthe surface condition of the base metal. In one embodiment of theinvention, the various steps of the pretreatment process for the basemetal are similar to the pretreatment process disclosed in U.S. Pat. No.5,395,702, which is incorporated herein. In another embodiment of theinvention, the pretreatment process includes, but is not limited to, anabrasion process; an absorbent process; solvent and/or cleaning solutionprocess; a low oxygen environment process; a rinse process; a picklingprocess; a chemical activation process; a flux treating process; and/oran intermediate barrier metal layer coating process. In one aspect ofthis embodiment, each of these pretreatment process can be use singly orin combination with one another. The type and/or number of pretreatmentprocess used generally depends on the type of base metal and/orcondition of the base metal surface. The pretreatment process can beapplied to a portion of the base metal surface or the complete surfaceof the base metal.

[0047] The abrasion process, absorbent process and/or solvent orcleaning process are designed to remove foreign materials and/or oxidesfrom the base metal surface. In one embodiment of the invention, theabrasion process includes, but is not limited to, the use of brushes,scrappers and the like to mechanically remove oxides and/or foreignmaterial from the surface of the base metal. In another embodiment ofthe invention, the absorbent process includes, but is not limited to,the use of absorbing materials (i.e. towels, absorbent paper products,sponges, squeegees, etc.) to mechanically remove oxides and/or foreignmaterial from the surface of the base metal. In still another embodimentof the invention, the solvent or cleaning process includes, but is notlimited to, the use of water, detergents, abrasives, chemical solvents,and/or chemical cleaners to remove oxides and/or foreign material fromthe surface of the base metal. The abrasion process, absorbent process,and/or solvent or cleaning process can be use individually or inconjunction with one another to remove foreign materials and/or oxidesfrom the base metal surface.

[0048] The low oxygen environment process is designed to inhibit theformation and/or reformation of oxides on the surface of the base metal.The low oxygen environment may take on several forms such as, but notlimited to, a low oxygen-containing gas environment and/or a lowoxygen-containing liquid environment. Examples of gases used in the lowoxygen-containing gas environments include, but are not limited to,nitrogen, hydrocarbons, hydrogen, noble gasses and/or othernon-oxidizing gasses. The one or more gases partially or totally shieldoxygen and/or other oxidizing elements or compounds from the base metal.In one embodiment of the invention, the low oxygen-containing gasenvironment includes nitrogen. Examples of liquids used in the lowoxygen-containing liquid environment include, but are not limited to,non-oxidizing liquids and/or liquids containing a low dissolved oxygencontent. The liquids partially or totally shield oxygen and/or otheroxidizing elements or compounds from the base metal. In anotherembodiment of the invention, the low oxygen-containing liquidenvironment includes heated water that is at least about 100-110° F. Instill another embodiment of the invention, the low oxygen-containingenvironment is applied to the base metal by spraying the lowoxygen-containing environment onto the surface of the base metal,partially or totally immersing the base metal in the lowoxygen-containing environment, and/or encasing the base metal in the lowoxygen-containing environment. In still yet another embodiment of theinvention, agitators are used in the low oxygen-containing liquidenvironment to facilitate in the removal of oxides and/or inhibit oxideformation on the base metal. The agitators can include brushes whichcontact the base metal.

[0049] The rinsed process is designed to remove foreign materials,oxides, pickling solution, deoxidizing agent, fluxes, solvents, and/orcleaning solutions from the surface of the base metal. In one embodimentof the invention, the rinse process includes the use of a rinse solutionthat includes a low or non-oxidizing liquid. In one aspect of thisembodiment, the low or non-oxidizing liquid includes water that is atleast about 70° F. In another embodiment of the invention, the rinsesolution can be applied to the surface of the metal strip by sprayingthe rinse solution onto the metal strip and/or partially or totallyimmersing the metal strip in the rinse solution. In yet anotherembodiment of the invention, the rinse solution is agitated tofacilitate in the cleaning of the base metal surface. In still anotherembodiment of the invention, the rinse solution is recirculated, dilutedand/or temperature is maintained during the rinsing process.

[0050] The pickling process is designed to remove a very thin surfacelayer from the base metal. The removal of the thin layer from the basemetal results in the partial or total removal of oxides and/or otherforeign matter from the base metal surface. The removal of the thinsurface layer from the base metal causes slight etching of the basemetal surface which results in the formation of microscopic valleys onthe base metal surface. These microscopic valleys increase the surfacearea to which the metal alloy and/or intermediate barrier metal layercan bond thereby facilitating in the formation of a stronger bondbetween the base metal and the metal alloy and/or intermetallic barriermetal layer. The pickling process includes the use of a picklingsolution which can be an acidic or a basic solution. In one embodimentof the invention, the pickling solution is an acidic solution. The acidcan be an organic acid, an inorganic acid, or combinations thereof. Inone aspect of this embodiment, the inorganic acid used in the picklingsolution includes, but are not limited to, hydrobromic acid, hydroiodicacid, choleic acid, perchloric acid, hydrofluoric acid, sulfuric acid,nitric acid, hydrochloric acid, phosphoric acid, and/or isobromic acid.In another aspect of this embodiment, the organic acid used in thepickling solution includes, but are not limited to, formic acid,propionic acid, butyric acid, and/or isobutyric acid. In anotherembodiment of the invention, the pickling solution includes a singleacid. Most base metal surfaces can be satisfactorily cleaned or pickledwith the use of a single acid. In one aspect of this embodiment, thepickling solution only includes an inorganic acid. In still anotherembodiment of the invention, the pickling solution includes two or moreacids. Some base metals are more difficult to clean or pickle. Stainlesssteel, as with other metals, is known to have surface oxides that aredifficult to remove. When coating stainless steel, it is very desirableto activate (i.e. remove surface oxides) the stainless steel surface soas to form a strong bond and uniformly coat the stainless steel basemetal. The chromium in the stainless steel surface reacts withatmospheric oxygen to form a chromium oxide film on the surface of thestainless steel. The chromium oxide film creates an almost impenetrablebarrier which protects the iron in the stainless steel from oxidizing.The chromium oxide film also forms a very tight and strong bond with thestainless steel, thus is not easily removable. Although the formation ofthe chromium oxide film is important in the corrosion-resistantproperties of the stainless steel and is intended for commercialstainless steel, the chromium oxide film can interfere with the bondingof the metal alloy coating to the stainless steel surface therebyresulting in weaker bond with the metal alloy coating, thus resulting inflaking of the metal alloy coating. The surface activation of astainless steel, as with other base metals, is accomplished by removingthe oxides on the surface of the base metal. The removal of the chromiumoxide film from the stainless steel surface activates the stainlesssteel surface. Testing of stainless steel has revealed that the removalof chromium oxide film improves the bonding of the metal alloy coatingand allows for thick and/or uniform metal alloy coatings to be formed.Oxide removal on other base metals also improves the bonding, coatinguniformity and/or coating thickness of the metal alloy coating. Picklingsolutions that include two or more acids typically can provide a morerapid oxide removal rate. As can be appreciated, the use of a picklingsolution that includes two or more acids is not limited to use onstainless steel or other base metals wherein oxide removal is difficult,but can be used on base metals to increase the rate of cleaning orpickling thereby reducing time for the pickling process. In one aspectof this embodiment, the pickling solution contains a combination ofhydrochloric acid and nitric acid. One specific formulation of this dualacid pickling solution is the pickling solution including about 5-25% byvolume hydrochloric acid and about 1-15% by volume nitric acid. A morespecific formulation of this dual acid pickling solution is the picklingsolution including about 5-15% by volume hydrochloric acid and about1-5% by volume nitric acid. A yet more specific formulation of this dualacid pickling solution is the pickling solution including about 10% byvolume hydrochloric acid and about 3% by volume nitric acid. In yetanother embodiment of the invention, the temperature of the picklingsolution is maintained to obtain the desired activity of the picklingsolution. In one aspect of this embodiment, the pickling solution ismaintained at a temperature of above about 26° C. In another aspect ofthis embodiment, the pickling solution is maintained at a temperature ofabout 48-60° C. In yet another aspect of this embodiment, the picklingsolution is maintained at a temperature of about 53-56° C. Higher acidconcentrations and/or higher acid temperatures will typically increasethe activity and aggressiveness of the pickling solution. In yet anotherembodiment of the invention, the pickling solution is agitated toprevent or inhibit the pickling solution from stagnating, varying inconcentration, varying in temperature, and/or to remove gas pocketswhich form on the base metal surface. In one aspect of this embodiment,the pickling solution is at least partially agitated by placingagitators in a pickling tank and/or by recirculating the picklingsolution in a pickling tank. Typically, agitation brushes in thepickling tank contacts base metal as it passes through the pickling tankto facilitate in oxide removal and cleaning of the base metal surface.In another embodiment of the invention, the base metal is exposed to thepickling solution for a sufficient time to properly clean and/or picklethe surface of the base metal. In one aspect of this embodiment, thetotal time for pickling the base metal is less than about 10 minutes. Inanother aspect of this embodiment, the total time for pickling the basemetal is less than about two minutes. In still another aspect of thisembodiment, the total time for pickling the base metal is less thanabout one minute. In still yet another aspect of this embodiment, thetotal time for pickling the base metal is about 5-60 seconds. In afurther aspect of this embodiment, the total time for pickling the basemetal is about 10-20 seconds. In still another embodiment, the picklingsolution is applied to the base metal by spray jets. In yet anotherembodiment, the base metal is partially or fully immersed in thepickling solution contained in a pickling tank.

[0051] The chemical activation process is designed to remove oxidesand/or foreign material from the base metal surface. In one embodimentof the invention, the chemical activation process includes subjectingthe base metal surface to a deoxidizing agent. Various types ofdeoxidizing agents may be used. In another embodiment of the invention,the deoxidizing agent includes zinc chloride. In one aspect of thisembodiment, the deoxidizing agent includes at least about 1% by volumezinc chloride. In another aspect of this embodiment, the deoxidizingagent includes at least about 5% by volume zinc chloride. The zincchloride removes oxides and foreign materials from the base metalsurface and/or provides a protective coating which inhibits oxideformation on the base metal surface. In still another embodiment of theinvention, the temperature of the zinc chloride solution is at leastabout ambient temperature (about 15-32° C.). In yet another embodiment,the deoxidizing solution is agitated to maintain a uniform solutionconcentration and/or temperature. In one aspect of this embodiment, theagitators include brushes which contact the base metal. In still yetanother embodiment of the invention, small amounts of acid are added tothe deoxidizing solution to enhance oxide removal. In one aspect of thisembodiment, hydrochloric acid is added to the deoxidizing solution. Inthis aspect, one formulation of the deoxidizing solution includes about1-50% by volume zinc chloride and about 0.5-15% by volume hydrochloricacid. In this aspect, another formulation of the deoxidizing solutionincludes about 5-50% by volume zinc chloride and about 1-15% by volumehydrochloric acid. In a further embodiment of the invention, the basemetal is subjected to the deoxidizing solution for less than about 10minutes. In one aspect of this embodiment, the base metal is subjectedto the deoxidizing solution for up to about one minute. In still afurther embodiment, the deoxidizing solution is applied to the basemetal by spray jets. In yet a further embodiment, the base metal ispartially or fully immersed in the deoxidizing solution contained in adeoxidizing tank.

[0052] The intermediate barrier metal process is designed to coat one ormore surface areas of the base metal with a thin metal coating. Theintermediate metal barrier is applied to part of or the complete surfaceof the base metal by a plating process, a plating and subsequent flowheating process, a metal spraying process, a coating roller process,and/or immersion process in molten metal prior to applying the metalalloy coating to the base metal surface. The intermediate barrier metaltypically provides additional corrosion resistance to the base metal inmany types of corrosive environments. In marine environments where thecoated base metal is exposed to salt and/or halogens (i.e. chlorine,fluorine, etc.), the use of an intermediate barrier metal cansignificantly extend the life of the coated base metal. The use of anintermediate barrier metal can also enhance the bonding of the metalalloy coating to the base metal. Some base metals such as, but notlimited to, stainless steel, form a weaker bond with certainformulations of the metal alloy. The application of an intermediatebarrier metal on part of or the complete surface of the base metal can,in many instances, improve the strength of the bond of the metal alloycoating to the base metal. The intermediate barrier metal is typicallytin, nickel, copper, and/or chromium. Other metals can be used for theintermediate barrier metal, such as, but not limited to, aluminum,cobalt, molybdenum, Sn—Ni, Fe—Ni, and/or zinc. Typically, oneintermediate barrier metal is formed on the surface of the base metal;however, more than one layer of one or more barrier metals can beapplied to the surface of the base metal to form a thicker intermediatebarrier metal layer, alter the composition of the intermediate barriermetal layer, alter the composition of the heat created intermetalliclayer if formed, and/or improve the bonding of the metal alloy coatingto the intermediate barrier metal layer and/or base metal. In oneembodiment of the invention, the intermediate barrier metal includesnickel. Typically, the nickel is flashed or plated to the base metalsurface. The nickling including intermediate barrier metal layerimproves corrosion-resistance of the base metal and/or metal alloy,especially against halogen containing compounds which can penetrate themetal alloy coating and attack and oxidize the surface of the base metalthereby weakening the bond between the base metal and the metal alloycoating. The nickel including intermediate barrier metal layer has alsobeen found to provide a formidable barrier to alcohols and/or varioustype of petroleum products. The metal alloy coating and nickel includingintermediate barrier metal effectively complement one another to providesuperior corrosion resistance. An intermediate barrier metal layer whichincludes nickel also improves the bonding of the metal alloy coating tothe base metal. The bond between the metal alloy coating and the nickellayer is surprisingly strong and durable and thereby inhibits the metalalloy coating from flaking. An intermediate barrier metal layer whichincludes nickel also inhibits the formation of a thick zinc layer in theintermetallic layer, when zinc is included in the metal alloy. Inanother embodiment of the invention, the intermediate barrier metalincludes tin, chromium and/or copper. An intermediate barrier metallayer which includes tin, chromium and/or copper improves the bonding ofthe metal alloy coating to the base metal. The tin, chromium and/orcopper in the intermediate barrier metal also has been found to inhibitadverse zinc intermetallic layer growth from the zinc in a zinccontaining metal alloy. A thick zinc layer can cause poor coatingquality or cracking of the coating during forming and bending, give riseto localized corrosion, and/or adversely affect performance of thecoated strip in particular applications. When copper is included in theintermediate barrier metal, the copper is typically plated onto thesurface of the base metal. The plated copper layer can be, but is notlimited to being, formed by passing the base metal through anelectroplating process or by adding copper sulfate to a picklingsolution and pickling the coated base metal. A copper containingintermediate barrier metal layer also enhances the corrosion-resistantproperties of the heat created intermetallic layer, improves the bondingof the metal alloy to the base metal, and/or improve the corrosionresistance of the metal alloy and/or base metal. When tin in included inthe intermediate barrier metal, the tin is typically coated onto thebase metal by immersion in molten metal, plating and/or metal spraying.A tin containing intermediate barrier metal advantageously changes thecomposition of the heat created intermetallic layer to form a highlycorrosion-resistant heat created intermetallic layer, improves thebonding of the metal alloy to the base metal, and/or improves thecorrosion-resistance of the metal alloy and/or base metal. When chromiumis included in the intermediate barrier metal, the chromium is typicallyplated onto the surface of the base metal. A chromium containingintermediate barrier metal layer advantageously changes the compositionof the heat created intermetallic layer to form a highlycorrosion-resistant heat created intermetallic layer, improves thebonding of the metal alloy, and/or improves the corrosion resistance ofthe metal alloy and/or base metal. In still another embodiment of theinvention, the intermediate barrier metal includes aluminum, cobalt,molybdenum, Sn—Ni, Fe—Ni, and/or zinc. The aluminum, cobalt, molybdenum,Sn—Ni, Fe—Ni, and/or zinc are typically plated to the base metal by aplating process. An intermediate barrier metal layer which includesaluminum, cobalt, molybdenum, Sn—Ni, Fe—Ni, and/or zinc improves thebonding of the corrosion resistant metal alloy coating to the basemetal, enhances the corrosion-resistant properties of the heat createdintermetallic layer, and/or improve the corrosion-resistance of themetal alloy and/or base metal. In yet another embodiment of theinvention, the thickness of the intermediate barrier metal layer is atleast about 0.3 micron. In one aspect of this embodiment, the thicknessof the intermediate barrier metal layer is at least about 1 micron. Inanother aspect of this embodiment, the thickness of the intermediatebarrier metal layer is less than about 500 microns. In yet anotheraspect of this embodiment, the thickness of the intermediate barriermetal layer is less than about 250 microns. In still another specificaspect of this embodiment, the thickness of the intermediate barriermetal layer is less than about 50 microns. In still yet another aspectof this embodiment, the thickness of the intermediate barrier metallayer is less than about 20 microns. In a further aspect of thisembodiment, the thickness of the intermediate barrier metal layer isabout 1-10 microns. In yet a further aspect of this embodiment, thethickness of the intermediate barrier metal layer is about 1-3 microns.In accordance with still yet another embodiment of the invention, theintermediate barrier metal layer is pre-heated and/or flow heated priorto applying the metal alloy coating to the base metal. The heating ofthe intermediate barrier metal layer to a sufficient temperature for asufficient amount of time causes a heat created intermetallic layer toform between the intermediate barrier metal layer and the base metal. Aheat created intermetallic layer is formed without the use of asubsequent heating step when the intermediate barrier metal is appliedto the base metal by a metal spraying process, a coating roller process,and/or an immersion process. The temperature of the intermediate barriermetal in the molten state causes a heat created intermetallic layer toform between the intermediate barrier metal and the base metal when themolten intermediate barrier metal contacts the surface of the basemetal. When the intermediate barrier metal is applied by a plating orpickling process, a subsequent heating step is needed to form the heatcreated intermetallic layer between the intermediate barrier metal andthe base metal. A “heat created intermetallic layer” is defined hereinas a metal layer formed by heat wherein the metal layer is a mixture ofat least the primary surface components of the base metal and componentsof a coated metal layer (i.e. intermediate barrier metal and/or metalalloy coating). The application of heat to the base metal and a coatedmetal layer causes the surface of the base metal to soften and/or meltand to combine with a portion of the soften or melted coated metallayer. In many instances, the formation of a heat created intermetalliclayer results in improved bonding of the coated metal to the base metal,and/or improves the corrosion-resistance of the base metal and/or coatedmetal layer. In one aspect of this embodiment, the thickness of the heatcreated intermetallic layer formed between the base metal and theintermediate barrier metal is at least about 0.1 micron. In anotheraspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the intermediatebarrier metal is at least about 0.3 micron. In still another aspect ofthis embodiment, the thickness of the heat created intermetallic layerformed between the base metal and the intermediate barrier metal is atleast about 0.5 micron. In still another aspect of this embodiment, thethickness of the heat created intermetallic layer formed between thebase metal and the intermediate barrier metal is at least about 1micron. In yet another aspect of this embodiment, the thickness of theheat created intermetallic layer formed between the base metal and theintermediate barrier metal is less than about 100 microns. In still yetanother aspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the intermediatebarrier metal is less than about 50 microns. In a further aspect of thisembodiment, the thickness of the heat created intermetallic layer formedbetween the base metal and the intermediate barrier metal is less thanabout 25 microns. In yet a further aspect of this embodiment, thethickness of the heat created intermetallic layer formed between thebase metal and the intermediate barrier metal is less than about 20microns. In still a further aspect of this embodiment, the thickness ofthe heat created intermetallic layer formed between the base metal andthe intermediate barrier metal is less than about 10 microns. In stillyet a further aspect of this embodiment, the thickness of the heatcreated intermetallic layer formed between the base metal and theintermediate barrier metal is about 1-10 microns. In still yet a furtheraspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the intermediatebarrier metal is about 1-5 microns. In still yet even a further aspectof this embodiment, the thickness of the heat created intermetalliclayer formed between the base metal and the intermediate barrier metalis about 1-3 microns. Typically the formation of a heat createdintermetallic layer takes at least a couple seconds to form. In oneembodiment of the present invention, the base metal is exposed to heatfor at least about 2 seconds to form the heat created intermetalliclayer between the base metal and the intermediate barrier metal. Thetime period of heat exposure for an intermediate barrier metal layerapplied by a plating and/or a pickling process is the time theintermediate barrier metal is exposed to heat after the plating and/orpickling process. The time period for heat exposure for an intermediatebarrier metal layer applied by metal spraying, coating rollers, and/orimmersion in molten metal includes the time of applying the intermediatebarrier metal to the base metal and the time the intermediate barriermetal is exposed to heat after the metal spraying, coating rollers,and/or immersion in molten metal process. Typically, the time of totalheat exposure is less than about four hours; however, greater heatexposure times can be used. In one aspect of this embodiment, the totaltime period of heat exposure to an intermediate barrier metal layerapplied to the base metal to form an intermetallic layer between thebase metal and the intermediate barrier metal layer is less than about20 minutes. In another aspect of this embodiment, the total time periodof heat exposure to an intermediate barrier metal layer applied to thebase metal to form an intermetallic layer between the base metal and theintermediate barrier metal layer is less than about 10 minutes. In yetanother aspect of this embodiment, the total time period of heatexposure to an intermediate barrier metal layer applied to the basemetal to form an intermetallic layer between the base metal and theintermediate barrier metal layer is less than about 5 minutes. In stillanother aspect of this embodiment, the total time period of heatexposure to an intermediate barrier metal layer applied to the basemetal to form an intermetallic layer between the base metal and theintermediate barrier metal layer is about 0.033-2 minutes. When heat isapplied to the coated base metal to form or further form the heatcreated intermetallic layer between the base metal and intermediatemetal barrier layer, the heat typically is applied by, but not limitedto, an oven and/or furnace, induction heating coils, lasers, heatexchanger, and/or radiation. As can be appreciated, the flow heating ofthe plated intermediated barrier layer can also function as a pre-heatprocess for the base metal. Alternatively, or in addition to, the heatcan be supplied by coating the base metal and the intermediated metalbarrier layer with a metal alloy by a hot-dip process. The heat from thehot-dip process causes the formation of the heat created intermetalliclayer. In still another embodiment of the invention, the application ofthe intermediate barrier metal layer on the surface of the base metal isa partial or complete pretreatment process for the surface of the basemetal prior to applying the metal alloy coating to the base metal. Theapplication of the an intermediate barrier metal to the surface of thebase metal forms a clean metal surface on the base metal surface. Due tothis clean metal surface, the application of the an intermediate barriermetal to the surface of the base metal can function as the solepretreatment process for the surface of the base metal. As can beappreciated, the surface of the base metal can be pretreated with otherpretreatment process prior to applying the intermediate barrier metallayer and/or pretreated with other pretreatment process subsequent toapplying the intermediate barrier metal layer.

[0053] In accordance with another aspect of the invention, metal alloycoating is coated on the base metal by a plating process or by a hot dipprocess. The coating process for the metal alloy coating can be by abatch or continuous process. As defined herein, a “hot dip process” forthe metal alloy is any process that coats the metal alloy coating on thebase metal and causes the formation of a heat created intermetalliclayer between the base metal and the metal alloy coating. Examples of ahot dip process include, but are not limited to, 1) plating a metalalloy coating partially or totally on the base metal and subsequentlyheating the plated layer until a heat created intermetallic layer formsbetween the plated layer and the base metal, 2) plating a metal alloypartially or totally on the base metal and subsequent partial or totalimmersion of the base metal in a molten bath of metal alloy for asufficient period of time to partially or totally coat the base metaland to form a heat created intermetallic layer between the coated metalalloy layer and the base metal, 3) plating a metal alloy partially ortotally on the base metal and subsequent spray coating molten metalalloy onto the base metal to partially or totally coating the base metalwherein the base metal is spray coated for a sufficient period of timeto form a heat created intermetallic layer between the coated metallayer and base metal, 4) plating a metal alloy partially or totally onthe base metal and subsequent partial or total immersion of the basemetal in a molten bath of metal alloy and spray coating molten metalalloy onto the base metal to partially or totally coat the base metalwherein the base metal is spray coated and immersed for a sufficientperiod of time to form a heat created intermetallic layer between thecoated metal layer and base metal, 5) partial or total immersion of thebase metal in a molten bath of metal alloy for a sufficient period oftime to partially or totally coat the base metal and to form a heatcreated intermetallic layer between the coated metal layer and the basemetal, 6) partial or total immersion of the base metal in a molten bathof metal alloy for a sufficient period of time to partially or totallycoat the base metal and spray coating molten metal alloy onto the basemetal to partially or totally coat the base metal wherein the base metalis immersed and sprayed for a sufficient period of time to form a heatcreated intermetallic layer between the coated metal layer and basemetal, 7) spray coating the base metal with molten metal alloy topartially or totally coat the base metal for a sufficient period of timeto form a heat created intermetallic layer between the coated metallayer and the base metal, 8) plating and subsequent heating andsubsequent immersion in molten metal alloy coating and/or spray coatingmolten metal alloy coating, 9) plating and subsequent heating andsubsequent immersion in molten metal alloy coating and/or spray coatingmolten metal alloy coating and subsequent heating after immersion inmolten metal alloy coating and/or spray coating molten metal alloycoating, 10) immersion in molten metal alloy coating and subsequentheating, 11) immersion in molten metal alloy coating and spray coatingmolten metal alloy coating and subsequent heating after immersion andspray coating, 12) spray coating molten metal alloy coating andsubsequent heating after spray coating, 13) coating molten metal alloyby coating rollers, 14) coating molten metal alloy by coating rollersand spray coating, 15) immersion in molten metal alloy and coatingmolten metal alloy by coating rollers, 16) plating and coating moltenmetal alloy by coating rollers, and 17) coating molten metal alloy bycoating rollers and subsequent heating. As can be appreciated, manyother hot dip coating combinations can be used. As further can beappreciated, the base metal can be coated a multiple of times by varioustypes of coated processes. When heat is subsequently applied to thecoated base metal to form or further form the heat created intermetalliclayer between the base metal and the metal alloy coating, the heattypically is applied by, but not limited by, an oven and/or furnace,induction heating coils, lasers, heat exchanger, and/or radiation. Inone embodiment of the invention, the thickness of the heat createdintermetallic layer is at least about 0.3 micron. In still anotheraspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the metal alloycoating is at least about 1 micron. In yet another aspect of thisembodiment, the thickness of the heat created intermetallic layer formedbetween the base metal and the metal alloy coating is less than about100 microns. In still yet another aspect of this embodiment, thethickness of the heat created intermetallic layer formed between thebase metal and the metal alloy coating is less than about 50 microns. Ina further aspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the metal alloycoating is less than about 25 microns. In yet a further aspect of thisembodiment, the thickness of the heat created intermetallic layer formedbetween the base metal and the metal alloy coating is less than about 20microns. In still a further aspect of this embodiment, the thickness ofthe heat created intermetallic layer formed between the base metal andthe metal alloy coating is less than about 10 microns. In still yet afurther aspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the metal alloycoating is about 1-5 microns. In still yet even a further aspect of thisembodiment, the thickness of the heat created intermetallic layer formedbetween the base metal and the metal alloy coating is about 1-3 microns.Typically, the formation of a heat created intermetallic layer takes atleast a couple seconds to form. In one embodiment of the invention, thebase metal is exposed to heat for at least 2 seconds to form the heatcreated intermetallic layer between the base metal and the metal alloycoating. The time period of heat exposure of a metal alloy coating layerapplied by a plating process is the time the metal alloy coating isexposed to heat after the plating process. The time period for heatexposure for a metal alloy coating layer applied by metal spraying,coating rollers and/or immersion in molten metal includes the time ofapplying the metal alloy coating to the base metal and the time themetal alloy coating is exposed to heat after the metal spraying, coatingrollers, and/or immersion in molten metal process. In one aspect of thisembodiment, the total time period of heat exposure to a metal alloycoating layer applied to the base metal to form an intermetallic layerbetween the base metal and the metal alloy coating layer is less thanabout 3 hours. In another aspect of this embodiment, the total timeperiod of heat exposure to a metal alloy coating layer applied to thebase metal to form an intermetallic layer between the base metal and themetal alloy coating layer is less than about 4 hours. In still anotheraspect of this embodiment, the total time period of heat exposure to ametal alloy coating layer applied to the base metal to form anintermetallic layer between the base metal and the metal alloy coatinglayer is less than about 2 hours. In yet another aspect of thisembodiment, the total time period of heat exposure to a metal alloycoating layer applied to the base metal to form an intermetallic layerbetween the base metal and the metal alloy coating layer is less thanabout 1 hour. In still yet another aspect of this embodiment, the totaltime period of heat exposure to a metal alloy coating layer applied tothe base metal to form an intermetallic layer between the base metal andthe metal alloy coating layer is less than about 30 minutes. In afurther aspect of this embodiment, the total time period of heatexposure to a metal alloy coating layer applied to the base metal toform an intermetallic layer between the base metal and the metal alloycoating layer is less than about 20 minutes. In yet further aspect ofthis embodiment, the total time period of heat exposure to a metal alloycoating layer applied to the base metal to form an intermetallic layerbetween the base metal and the metal alloy coating layer is less thanabout 10 minutes. In still a further another aspect of this embodiment,the total time period of heat exposure to a metal alloy coating layerapplied to the base metal to form an intermetallic layer between thebase metal and the metal alloy coating layer is less than about 5minutes. In still yet further aspect of this embodiment, the total timeperiod of heat exposure to a metal alloy coating layer applied to thebase metal to form an intermetallic layer between the base metal and themetal alloy coating layer is about 0.033-2 minutes. In still a furtheraspect of this embodiment, the total time period of heat exposure to ametal alloy coating layer applied to the base metal to form anintermetallic layer between the base metal and the metal alloy coatinglayer is about 0.033-0.5 minutes. In yet a further aspect of thisembodiment, the total time period of heat exposure to a metal alloycoating layer applied to the base metal to form an intermetallic layerbetween the base metal and the metal alloy coating layer is about0.083-0.5 minutes.

[0054] The metal alloy coating formed on the surface of the base metalby a batch coating process or by a continuous coating process can resultin different types of coatings. These differences can include, but arenot limited to, the following:

[0055] a) Uniformity of coating (weight and thickness)

[0056] b) Surface appearance

[0057] c) Smoothness

[0058] d) Texture control

[0059] e) Control of intermetallic phases (growth and uniformity)

[0060] A base metal coated in a continuous coating process typicallyproduces a coated base metal having superior uniformity of coating(weight and thickness), superior metallographic structure, superiorsurface appearance, superior smoothness, superior spangle size, andfewer surface defects. Furthermore, the composition of the heat createdintermetallic layer is typically superior as compared to a base metalcoated in a batch coating process. In addition to surface appearance anduniformity of thickness, the formability of the coated base metal isgenerally better due to a more uniform coating thickness on the surfaceof the base metal. In general, thicker coatings provide greatercorrosion protection, whereas thinner coatings tend to give betterformability and weldability. Thinner coatings with uniformity ofthickness can be better formed by a continuous coating process.

[0061] In still another aspect of the invention, the metal alloy coatingis applied to the surface of the base metal, the surface of theintermediate barrier metal layer, and/or an existing metal alloy coatingby a plating process. When a plating process is used, a heat createdintermetallic layer is not formed between the metal alloy coating andthe surface of the base metal, the surface of the intermediate barriermetal layer, and/or a previously applied metal alloy coating. Typically,the plating process is carried out by standard plating processes, thus adetailed description of a plating process is not described herein. Thecomplete or partial surface of the base metal, the surface of theintermediate barrier metal layer, and/or surface of a previously appliedmetal alloy can be coated by the plating process. The plating of thecomponents of the corrosion resistant metal alloy can be accomplished atthe same time or in subsequent steps. For instance, a corrosionresistant tin metal alloy which includes lead can be plated by a)simultaneously plating the tin and lead onto the surface of the basemetal, the surface of the intermediate barrier metal layer, and/or metalalloy coating, b) first plating the tin on the surface of the basemetal, the surface of the intermediate barrier metal layer and/or metalalloy coating, and subsequently plating the lead on the surface of thebase metal, the surface of the intermediate barrier metal layer, and/ormetal alloy coating, or c) first plating the lead on the surface of thebase metal, the surface of the intermediate barrier metal layer, and/ormetal alloy coating, and subsequently plating the tin on the surface ofthe base metal, the surface of the intermediate barrier metal layer,and/or metal alloy coating. Similarly, a corrosion resistant tin andzinc metal alloy which includes antimony can be plated by a)simultaneously plating the tin, zinc and antimony onto the surface ofthe base metal, the surface of the intermediate barrier metal layer,and/or metal alloy coating, b) first plating the tin on the surface ofthe base metal, the surface of the intermediate barrier metal layer,and/or metal alloy coating, then plating the zinc on the surface of thebase metal, the surface of the intermediate barrier metal layer, and/ormetal alloy coating, and subsequently plating the antimony on thesurface of the base metal, the surface of the intermediate barrier,metal layer, and/or metal alloy coating, c) first plating the zinc onthe surface of the base metal, the surface of the intermediate barriermetal layer, and/or metal alloy coating, then plating the tin on thesurface of the base metal, the surface of the intermediate barrier metallayer, and/or metal alloy coating, and subsequently plating the antimonyon the surface of the base metal, the surface of the intermediatebarrier metal layer, and/or metal alloy coating, d) first plating theantimony on the surface of the base metal, the surface of theintermediate barrier metal layer, and/or metal alloy coating, andsubsequently simultaneously plating tin and zinc on the surface of thebase metal, the surface of the intermediate barrier metal layer, and/ormetal alloy coating, etc. In one embodiment of the invention, a tinmetal alloy is plated on the surface of the base metal. In one specificaspect of this embodiment, the plating process includes the plating oftin in an electrolytic solution containing stannous tin and an acid. Inanother embodiment of the invention, a tin and zinc metal alloy isplated on the surface of the base metal. In one specific aspect of thisembodiment, the plating process includes the plating of tin and zinc inan electrolytic solution containing stannous tin, zinc and an acid.

[0062] In yet another aspect of the invention, the metal alloy coatingis applied to the surface of the base metal, the surface of theintermediate barrier metal layer, and/or previously applied metal alloycoating by a hot dip process that includes plating and subsequentheating of the plated metal alloy. The metal alloy is plated onto thesurface of the base metal, the surface of the intermediate barrier metallayer, and/or a previously applied metal alloy coating by a platingprocess that is the same as or similar to the plating process describedabove. After the metal alloy is plated onto the surface of the basemetal, the surface of the intermediate barrier metal layer, and/orpreviously applied metal alloy coating, the plated metal alloy coatingis subjected to heat for a sufficient period of time to form a heatcreated intermetallic layer between the plated metal alloy coating andthe surface of the base metal, the surface of the intermediate barriermetal layer, and/or the surface of the previously applied metal alloycoating. If one or more of the components of the corrosion resistantmetal alloy coating were plated by a separate plating process, theplated metal components of the metal alloy coating can be subjected toheat after one or more of the plating processes, or after all thecomponents of the metal alloy coating have been coated onto the surfaceof the base metal, the surface of the intermediate barrier metal layer,and/or the surface of the previously applied metal alloy coating. Theheating of the plated metal alloy coating causes at least a portion ofthe alloy to enter a molten state and to form an at least partiallyuniform and substantially level coating layer. The heating of the platedmetal alloy coating also facilitates in the reduction and/or eliminationof pin holes in the metal alloy coating which may have formed during theplating process. The time period selected for flow heating the platedmetal alloy coating depends on the time necessary to soften and/or meltthe desired amount of tin in the tin metal alloy coating or tin and zincin the tin and zinc metal alloy coating to form the desired thickness ofthe heat created intermetallic layer. When one or more of the componentsof the corrosion resistant metal alloy coating are plated by separateplating process, the plated metal components of the metal alloy coatingare subjected to heat for a sufficient period of time to at leastpartially alloy together the components of the metal alloy coating. Theheating process for the plate metal alloy can be by a batch or by acontinuous process. In one embodiment of the invention, the plated metalalloy coating is exposed to heat by the application of another moltenmetal alloy coating onto the surface of the plated metal alloy coating.The heat of the molten metal alloy upon contact with the plated metalalloy causes the components of the plated metal alloy coating to atleast partially alloy together and/or form the desired thickness of theheat created intermetallic layer between the plated metal alloy coatingand the surface of the base metal, the surface of the intermediatebarrier metal layer, and/or the surface of the previously applied metalalloy coating. In one aspect of this embodiment, a molten metal alloy isapplied by immersion is coated onto the surface of the plated metalalloy coating. In another aspect of this embodiment, a molten metalalloy is applied by coating rollers is coated onto the surface of theplated metal alloy coating. In still another aspect of this embodiment,a molten metal alloy is applied by spray coating is coated onto thesurface of the plated metal alloy coating. In another embodiment of theinvention, the plated metal alloy coating is exposed to an external heatsource for a time period and temperature sufficient to at leastpartially alloy together the components of the plated metal alloycoating and/or form the desired thickness of the heat createdintermetallic layer between the plated metal alloy coating and thesurface of the base metal, the surface of the intermediate barrier metallayer, and/or the surface of the previously applied metal alloy coating.The plated metal alloy coating is typically exposed to heat through theuse of a convection oven, a furnace, heated fluids, flames, inductionheating, lasers, hot gasses, radiation, and the like. In one aspect ofthis embodiment, the temperature the plated metal alloy is exposed to isat least about 200° C. In another aspect of this embodiment, thetemperature the plated metal alloy is exposed to is less than about2000° C. In still another aspect of this embodiment, the temperature theplated metal alloy is exposed to is less than about 1000° C. In yetanother aspect of this embodiment, the temperature the plated metalalloy is exposed to is less than 500° C.

[0063] In accordance with still yet another aspect of the invention, thecorrosion resistant metal alloy is coated onto the surface of the basemetal, the surface of the intermediate barrier metal layer, and/or thesurface of the previously applied metal alloy coating by immersion intomolten corrosion resistant metal alloy. In one embodiment of theinvention, the molten corrosion resistant metal alloy is maintained at atemperature of at least about 232° C. (449° F.). In one aspect of thisembodiment, the molten corrosion resistant metal alloy is maintained ata temperature of at least about 2-30° C. above the melting point of thecorrosion resistant metal alloy. In another embodiment of the invention,the residence time of the base metal in the molten corrosion resistantalloy is selected to form the desired heat created intermetallic layerbetween the corrosion resistant alloy metal coating and the surface ofthe base metal, the surface of the intermediate barrier metal layer,and/or the surface of the previously applied metal alloy coating. In oneaspect of this embodiment, the residence time of the base metal in themolten metal alloy is at least about 0.033-0.083 minutes. In anotheraspect of this embodiment, the residence time of the base metal in themolten metal alloy is less than about 10 minutes. In still anotheraspect of this embodiment, the residence time of the base metal in themolten metal alloy is less than about two minutes. In yet another aspectof this embodiment, the residence time of the base metal in the moltenmetal alloy is less than about one minute. In still yet another aspectof this embodiment, the residence time of the base metal in the moltenmetal alloy is about 0.083-0.5 minutes.

[0064] In accordance with another aspect of the invention, the hot dipcoating of the base metal by immersion in molten metal alloy includesthe use of a flux box. The flux box is designed to receive the basemetal prior to the base metal passing into the molten metal alloy. Theflux solution in the flux box is formulated to remove residual oxidesfrom the base metal surface, shield the surface of the base metal, thesurface of the intermediate barrier metal layer, and/or the surface ofthe previously applied metal alloy coating from oxygen until the surfaceof the base metal, the surface of the intermediate barrier metal layer,and/or the surface of the previously applied metal alloy coating basemetal is coated with the molten metal alloy, inhibit the formation ofviscous oxides at the point where the base metal enters the molten metalalloy, and/or inhibits dross formation on the base metal. The exposureof the base metal to the flux solution is the last pretreatment processof the base metal prior to being coated by immersion in molten metalalloy. In one embodiment of the invention, the flux box contains a fluxsolution which has a lower specific gravity than the molten metal alloy,thus the flux solution floats on the surface of the molten alloy. Inanother embodiment of the invention, the flux solution includes a zincchloride solution. In one aspect of this embodiment, the flux solutionincludes ammonium chloride. In another aspect of this embodiment, theflux solution includes about 20-75% by volume zinc chloride. In yetanother aspect of this embodiment, the flux solution includes zincchloride and ammonium chloride. In still yet another aspect of thisembodiment, the flux solution includes about 20-75% by volume zincchloride and up to about 40% by volume ammonium chloride. In a furtheraspect of this embodiment, the flux solution includes about 30-60% byvolume zinc chloride and up to about 1-20% by volume ammonium chloride.In yet a further aspect of this embodiment, the flux solution includesabout 50% by volume zinc chloride and about 8% by volume ammoniumchloride.

[0065] In accordance with still another aspect of the invention, the hotdip process of coating the base metal is by immersion in a molten metalalloy includes a melting pot for heating the molten metal alloy. In oneembodiment of the invention, the melting pot is heated by heating coils,heating rods, gas jets, induction heating, lasers, radiation, etc. Inone aspect of this embodiment, the melting pot is heated by at least onegas jet directed toward at least one side of the melting pot. In anotheraspect of this embodiment, heating coils and heating rods are used toheat the metal alloy directly in the melting pot. In still anotheraspect of this embodiment, gas jets are used heat the molten metal alloyin the melting pot.

[0066] In accordance with a further aspect of the invention, the hot dipprocess of coating the base metal by immersion in molten metal alloyincludes the use of a protective material on the surface of the moltenmetal alloy in the melting pot. The protective material is formulated toat least partially shield the molten metal alloy from the atmospherethereby preventing or inhibiting oxide formation on the surface of themolten metal alloy, and/or preventing or inhibiting dross formation onthe coated base metal as the coated base metal enters and/or exits fromthe melting pot. In one embodiment of the invention, the protectivematerial has a specific gravity which is less than the specific gravityof the molten metal alloy so that the protective material at leastpartially floats on the surface of the molten metal alloy. In anotherembodiment of the invention, the protective material includes an oil. Inone aspect of this embodiment, the protective material includes palmoil. When the protective material is palm oil, the melting point of themetal alloy should be below about 344° C., the degrading point of palmoil. For metal alloys having a higher melting point, other oils, fluxes,or other materials and/or special cooling processes for the protectivematerial are employed when a protective material is used. In stillanother embodiment, the protective material facilitates in forming asmooth and uniform coating on the surface of the base metal.

[0067] In accordance with another aspect of the invention, the thicknessof the metal alloy coating by immersion in molten metal alloy is atleast partially regulated by the residence time of the base metal in themolten metal alloy, the temperature of the molten metal alloy in themelting pot, and/or the speed at which the base metal moves through themolten metal alloy. In one embodiment of the invention, the base metalis maintained at a substantially constant speed through the molten metalalloy. The substantially uniform speed results in a substantiallyuniform growth of the heat created intermetallic layer between the metalalloy and the base metal, a substantially smooth coating of metal alloy,and/or a substantially constant metal alloy coating thickness. As thebase metal passes through the molten metal alloy at a substantiallyconstant speed, the metal alloy adheres to the moving base metal andshears a portion of the metal alloy coating from the moving base metal.The shearing effect results from the viscosity of the molten alloy andthe speed of the moving base metal. For a given speed and metal alloyviscosity, a certain thickness of metal alloy will be applied to thebase metal over a given time. The shearing effect results in asubstantially uniform coating, excellent surface appearance, excellentsmoothness, excellent texture control and a substantially uniform heatcreated intermetallic layer. In another embodiment of the invention, thebase metal is coated by moving the base metal through the molten metalalloy in the melting pot at a relatively constant speed of about 1-400ft/min. In one aspect of this embodiment, the base metal is movedthrough the molten metal alloy in the melting pot at a relativelyconstant speed of about 50-250 ft/min.

[0068] In accordance with still another aspect of the invention, thecorrosion resistant metal alloy is coated onto the surface of the basemetal, the surface of the intermediate barrier metal layer, and/or thesurface of the previously applied metal alloy coating by a coatingroller process. Molten metal alloy on the coating rollers is applied tothe surface of the base metal, the surface of the intermediate barriermetal layer, and/or the surface of the previously applied metal alloycoating by a coating roller process as the base metal passes by orbetween one or more coating rollers. The coating rollers form a smoothand/or uniform metal alloy coating layer on the base metal. The coatingrollers press against and coat the surface of the base metal, thesurface of the intermediate barrier metal layer, and/or the surface ofthe previously applied metal alloy coating and fill pin holes oruncoated surfaces on the surface of the base metal, the surface of theintermediate barrier metal layer, and/or the surface of the previouslyapplied metal alloy coating by a coating roller process. The coatingrollers also control the thickness of the metal alloy coating onto thesurface of the base metal, the surface of the intermediate barrier metallayer, and/or the surface of the previously applied metal alloy coatingby a coating roller process. In one embodiment of the invention, thecoating rollers are used in conjunction with an immersion process and/ormetal spray process. In another embodiment, the coating rollers arespaced apart a sufficient distance so that the base metal can passbetween the coating rollers. As the base metal basses between one ormore sets of coating rollers, the coating rollers maintain a desiredcoating thickness of the metal alloy on the base metal, remove excessmetal alloy from the base metal, and/or coat any non-coated regions onthe surface of the base metal. In one aspect of this embodiment, thecoating thickness of the metal alloy is selected to ensure thatessentially no uncoated regions exist on the surface of the base metal.Typically, the thickness of the metal alloy on the surface of base metalis at least about 1 micron, and generally at least about 2.5 microns,more generally about 7 to 2550 microns, and even more generally about7-1270 microns. In another aspect of this embodiment, the coatingthickness of the metal alloy is selected to ensure the coated metalalloy has essentially no pin holes, and/or does not shear when formedinto various products. A metal alloy coating thickness of about 25-51microns forms a coating that has few, if any, pin holes, providesgreater elongation characteristics, and resist shearing when formed intovarious shaped articles. In still another aspect of this embodiment, thethickness of the metal alloy is selected for use in certain types ofenvironments in which the coated base metal is to be used. A metal alloycoating thickness of about 25-51 microns forms a coating thatsignificantly reduces the corrosion of the base metal in virtually alltypes of environments. Metal alloy coating thicknesses greater thanabout 51 microns are typically used in harsh environments to provideadded corrosion protection. In another embodiment of the invention, themolten metal alloy is maintained at a temperature at least about 2-30°C. above the melting point of the metal alloy, while the metal alloy ison the coating rollers. In another embodiment of the invention, thecoating processes includes at least one set of coating rollers thatpartially or fully coat the surface of the base metal as the base metalpasses the coating rollers. In another embodiment of the invention, oneor more coating rollers are at least partially immersed in molten metalalloy during the coating process. In one aspect of this embodiment, thecoating process is used in conjunction with an immersion coating processand one or more of the coating rollers are at least partially immersedin molten metal alloy in the melting pot. In another aspect of thisembodiment, one or more of the coating rollers are at least partiallyimmersed in a protective material in the melting pot. In yet anotherembodiment of the invention, one or more coating rollers are positionedabove the molten metal allot in the melting pot when the coating rollersare used in conjunction with an immersion coating process. In stillanother embodiment of the invention, one or more coating rollers are atleast partially coated with molten metal alloy by one or more spray jetsthat direct molten metal alloy on to the one or more coating rollers.The one or more spray jets direct the molten metal alloy on to thesurface of the coating rollers as the base metal passes by or betweenthe coating rollers thereby resulting in the base metal being partiallyor completely coated with the metal alloy. In still another embodimentof the invention, one or more coating rollers includes an internalcavity in which molten metal alloy is directed into and then directedonto the surface of the coating roller to direct the molten metal alloyon to the surface of the coating rollers as the base metal passes by orbetween the coating rollers. In still another embodiment of theinvention, the time period the base metal is exposed to each coatingroller is a relatively short time. The time period is dependant on thespeed of the base metal and the size of the coating rollers. Typically,the base metal is exposed to the coating rollers for at least about 0.3seconds and generally about 0.5-30 seconds. In a further embodiment, oneor more coating rollers include one or more grooves. The one or moregrooves are designed to facilitate in maintaining the molten metal alloyon the coating roller during the coating process.

[0069] In accordance with yet another aspect of the present invention,the corrosion resistant metal alloy is coated onto the surface of thebase metal, the surface of the intermediate barrier metal layer, and/orthe surface of the previously applied metal alloy coating by a spraycoating process. Molten metal alloy is sprayed onto the surface of thebase metal, the surface of the intermediate barrier metal layer, and/orthe surface of the previously applied metal alloy coating by one or morespray jets. The spray jets spray molten metal alloy onto the surface ofthe base metal, the surface of the intermediate barrier metal layer,and/or the surface of the previously applied metal alloy coating to atleast partially coat the surface of the base metal, the surface of theintermediate barrier metal layer, and/or the surface of the previouslyapplied metal alloy coating, and/or ensure that a uniform and/orcontinuous coating is applied on the surface of the base metal, thesurface of the intermediate barrier metal layer, and/or the surface ofthe previously applied metal alloy coating. The speed and time thesurface of the base metal, the surface of the intermediate barrier metallayer, and/or the surface of the previously applied metal alloy is incontact with the molten metal is controlled so that the desired coatingthickness and desired thickness of the heat created intermetallic layeris obtained. In one embodiment of the invention, the spray jets are usedin conjunction with coating rollers and/or an immersion process. In oneaspect of this embodiment, the spray jets at least partially directmolten metal alloy onto the coating rollers and/or onto the surface ofthe base metal, the surface of the intermediate barrier metal layer,and/or the surface of the previously applied metal alloy coating duringthe coating process. In another embodiment of the invention, this moltenmetal alloy is maintained at a temperature of at least about 2-30° C.above the melting point of the metal alloy as the metal alloy is sprayedfrom the one or more spray jets. In yet another embodiment of theinvention, the base metal passes by or between one or more metal sprayjets during the coating process to partially or completely coat thesurface of the base metal. In another embodiment of the invention, thebase metal is exposed to the molten metal alloy from the one or moremetal spray jets for a sufficient time to partially or fully coat thesurface of the base metal. The time the base metal is exposed to themolten metal alloy from the metal spray jets is dependent on the speedof the moving base metal. Typically, the base metal is exposed to themolten metal alloy from the metal spray jets for at least about 0.3seconds, generally about 0.5-60 seconds, and preferably about 1-30seconds.

[0070] In accordance with another aspect of the present invention, thecoated base metal which is coated by a hot dip process is subjected toan air-knife process. In an air-knife process, the coated metal alloy issubjected to a high velocity fluid. The high velocity fluid removessurplus molten corrosion resistant metal alloy coating from the surfaceof the base metal, the surface of the intermediate barrier metal layer,and/or the surface of the previously applied metal alloy coating; smearsthe coated corrosion resistant metal alloy over the surface of the basemetal, the surface of the intermediate barrier metal layer, and/or thesurface of the previously applied metal alloy coating thereby reducingor eliminating pin holes or other uncoated surfaces; improves the grainsize of the coated metal alloy; smooths and/or reducing lumps or ribs inthe coated metal alloy; reduces the metal alloy coating thickness;and/or cools and/or hardens the molten metal alloy. In one embodiment ofthe invention, the air knife process uses a high velocity fluid whichgenerally does not oxidize the corrosion resistant alloy. In one aspectof this embodiment, the fluid used in the air-knife process includes,but is not limited to, an inert or substantially inert gas such as, butnot limited to, nitrogen, sulfur hexafluoride, carbon dioxide, hydrogen,noble gases, and/or hydrocarbons. In another embodiment of theinvention, the high velocity fluid of the air-knife process is directedonto both sides of the coated base metal and at a direction which is notperpendicular to the surface of the coated base metal. In still anotherembodiment of the invention, the protective material on the surface ofthe molten metal alloy in the melting pot is eliminated when theair-knife process is used in conjunction with a coating process byimmersion in molten alloy. When an air-knife process is used inconjunction with coating by immersion, the inert or substantially inertfluid inhibits or prevents dross formation and/or viscous oxideformation in the region in which the inert or substantially inert fluidcontacts the molten metal alloy in the melting pot. The high velocity ofthe inert or substantially inert fluid also breaks up and/or pushes awaydross or viscous oxides on the surface of the molten metal alloy thusforming a dross and oxide free region for the coated base metal to beremoved from the melting pot. In yet another embodiment of theinvention, the air-knife process includes one or more blast nozzles todirect a high velocity fluid toward the metal alloy coating on thesurface of the base metal. In one aspect of this embodiment, the coatedbase metal is directed between two or more blast nozzles. In still yetanother embodiment, the air-knife process at least partially causesmolten metal alloy on the surface of the base metal to be directed backinto the melting pot when the air-knife process is used in conjunctionwith an immersion coating process. In a further embodiment, one or moreblast nozzles are adjustable so as to direct the high velocity fluid atvarious angles onto the surface of the coated base metal. In yet afurther embodiment of the invention, one or more blast nozzles arepartially or fully enclosed in a chamber, which chamber is designed toaccumulate or trap at least a portion of the fluid after the fluid isdirected toward the base metal. The accumulated fluid can then berecirculated back through the blast nozzles. In still a furtherembodiment of the invention, the air-knife process is used to controlthe thickness and/or quality of the molten metal alloy coating. In stillyet a further embodiment of the invention, the base metal is exposed tothe fluid from the air-knife process for a relatively short period oftime. The time the base metal is exposed to the fluid is dependent onthe speed of the moving base metal. Typically, the base metal is exposedto the fluid from the air-knife process for at least about 0.3 seconds,generally about 0.5-60 seconds, and preferably about 1-30 seconds.

[0071] In accordance with another aspect of the present invention, thecoated base metal is cooled by a cooling process. Typically the coatedbase metal is cooled after being coated by a hot dip coating process.The coated base metal can be cooled by spraying with and/or subjectingthe coated base metal to a cooling fluid and/or immersing the coatedbase metal in a cooling fluid. As previously stated, when an air-knifeprocess is used, the coated base metal can be at least partially cooledby the fluid from the air-knife process. When the heated corrosionresistant metal alloy slowly cools, larger grain sizes and lower graindensities generally occur in the corrosion resistant metal alloycoating, and the corrosion resistant metal alloy coating typically formsa more reflective surface. When the heated corrosion resistant metalalloy rapidly cools, fine grain sizes and increased grain densitiesoccur in the corrosion resistant metal alloy coating, and the corrosionresistant metal alloy coating forms a less reflective surface than aslowly cooled corrosion resistant alloy coating. Small grain sizes andhigher grain densities in the corrosion resistant metal alloy coatingtypically result in a stronger bonding coating and greater corrosionresistance. In one embodiment of the invention, the cooling process isless than about two hours. In one aspect of this embodiment, the coolingprocess is less than about one hour. In another aspect of thisembodiment, the cooling process is less than 10 minutes. In stillanother aspect of this embodiment, the cooling process is less thanabout 5 minutes. In another embodiment of the invention, a liquid or gasis jet sprayed onto the surface of the coated base metal to cool themetal alloy coating. In one aspect of this embodiment, the cooling fluidis water. In another aspect of this embodiment, the temperature of thecooling fluid is about 15-95° C. In yet another aspect of thisembodiment, the temperature of the cooling fluid is about 20-60° C. Inyet another aspect of this embodiment, the temperature of the coolingfluid is about ambient temperature (20-28° C.). In still yet anotheraspect of this embodiment, the coated base metal is at least partiallyguided by a camel-back guide as the coated base metal is cooled by thespray jets. The camel-back guide is designed to minimize contact withthe coated base metal thereby reducing the amount of metal alloy coatinginadvertently removed from the base metal. In one aspect of thisembodiment, the camel-back design allows cooling fluid to be applied toboth sides of the coated base metal. In still another embodiment of theinvention, the coated metal alloy is cooled by immersion in a coolingfluid. Typically, the coated base metal is directed into a cooling tankthat contains a cooling fluid. In one aspect of this embodiment, thetemperature of the cooling fluid in the cooling tank is maintained at adesired temperature by use of agitators, heat exchangers, and/orreplenishment of cooling fluid. In another aspect of this embodiment,the temperature of the cooling fluid is about 15-95° C. In yet anotheraspect of this embodiment, the temperature of the cooling fluid is about20-60° C. In yet another aspect of this embodiment, the temperature ofthe cooling fluid is about ambient temperature (20-28° C.). In still yetanother aspect of this embodiment, water is used as the cooling fluid.The oxygen in the water can cause discoloration of the metal alloycoating thereby reducing the reflectiveness of the metal alloy coating.

[0072] In accordance with another aspect of the invention, the coatedbase metal is passed through a leveler whereby the coated metal alloy ismolded about the base metal, and/or smoothed. In one embodiment of theinvention, a final coating thickness is obtained by the leveler. Inanother embodiment of the invention, the leveler includes a plurality ofrollers. In yet another embodiment of the invention, the base metal ismaintained at a tension as it is passed through the leveler.

[0073] In accordance with yet another aspect of the invention, thecoated base metal is rolled into a coil for later processing or use.

[0074] In accordance with still another aspect of the invention, thecoated base metal is sheared into specific length plates or strip forlater use or immediate processing. In one embodiment of the invention, ashearing device shears a continuously moving coated base metal. In oneaspect of this embodiment, the shearing device moves with the movingcoated base metal when shearing.

[0075] In accordance with still yet another aspect of the presentinvention, the heat created intermetallic layer formed between the metalalloy coating and the surface of the base metal, surface of theintermediate barrier metal layer, and/or surface of a previously appliedmetal alloy coating is at least partially exposed. The exposed heatcreated intermetallic layer has been found to provide excellentcorrosion resistance in a number of environments. The heat createdintermetallic layer can be exposed by mechanical and/or chemicalprocesses. In one embodiment of the invention, at least a portion of themetal alloy coating is removed by a mechanical process that includes,but is not limited to, grinding, melting, shearing and the like. Inanother embodiment of the invention, at least a portion of the metalalloy coating is removed by a chemical process which includes, but isnot limited to, an oxidation process. The oxidation process at leastpartially removes the coated metal alloy and at least partially exposesthe heat created intermetallic layer. The oxidation process includes theuse of an oxidizing solution. In one aspect of this embodiment, theoxidation solution is selected to be autocatalytic in that the oxidationsolution removes the metal alloy coating but does not or only veryslowly removes the heat created intermetallic layer. In another aspectof this embodiment, the oxidation solution includes nitric acid and/orchromic acid. When nitric acid is included in the oxidation solution,the nitric acid concentration is generally about 5-60% by volume andtypically about 10-25% by volume of the oxidation solution. In stillanother aspect of this embodiment, the oxidation solution includescopper sulfate. When copper sulfate is included in the oxidationsolution, the copper sulfate is generally less than about 10% by volume,typically about 0.5-2% by volume of the oxidation solution, andpreferably about 1% by volume of the oxidation solution. In yet anotheraspect of this embodiment, the exposure of the coated base metal to theoxidation solution in the oxidation process is generally less than aboutone hour; however, longer times can be used depending on theconcentration and temperature of the oxidation solution, the type ofmetal alloy, the thickness of the metal alloy, and/or the degree ofdesired exposure of the heat created intermetallic layer. In onespecific aspect, the exposure to the oxidation solution in the oxidationprocess is less than about ten minutes. In another specific aspect, theexposure to the oxidation solution in the oxidation process is less thanabout two minutes. In still another specific aspect, the exposure to theoxidation solution in the oxidation process is about 0.08-1.5 minutes.In a further aspect of this embodiment, after a sufficient amount of theheat created intermetallic layer is exposed by the oxidation solution,the oxidation solution is removed from the base metal. In still afurther aspect this embodiment, the temperature of the oxidationsolution is about 15-80° C. In yet a further aspect this embodiment, thetemperature of the oxidation solution is about 30-80° C. In yet afurther aspect this embodiment, the temperature of the oxidationsolution is about 15-60° C. In a further aspect this embodiment, thetemperature of the oxidation solution is about 12-62° C. In yet afurther aspect this embodiment, the temperature of the oxidationsolution is about 40-60° C. In yet a further aspect this embodiment, thetemperature of the oxidation solution is about 22-42° C. In still afurther aspect this embodiment, the temperature of the oxidationsolution is about 32° C. In still yet a further aspect of thisembodiment, the oxidation solution is rinsed off after the intermetalliclayer is exposed. In still another embodiment of the invention, the atleast partial removal of the metal alloy coating is described in U.S.Pat. No. 5,397,652, which is incorporated herein.

[0076] In accordance with another aspect of the present invention, theexposed heat created intermetallic layer is passivated by a passivationprocess. The passivation process is designed to at least partially reactwith the heat created intermetallic layer and to form a thin corrosionresistant layer. The corrosion resistant layer exhibits improvedcorrosion resistant properties, improved abrasion resistance, improvedhardness, improved formality, resists cracking, and/or has lessreflective color as compared to a non-passified intermetallic layer. Thepassivation process includes the use of a passivation solution. In oneembodiment of the invention, the passivation solution includes anitrogen containing compound. In another embodiment of the invention,the passivation solution is the same as the oxidation solution, thus theoxidation/passivation solution removes the metal alloy to expose theheat created intermetallic layer and subsequently passifies the exposedheat created intermetallic layer to form the corrosion resistant layer.In one aspect of this embodiment, the oxidizing solution fully orsubstantially ceases to react with the intermetallic layer after thepassivation later is formed (auto-catalytic). In another embodiment ofthe invention, the coated base metal material is passivated in adifferent tank from the oxidation solution. In yet another embodiment ofthe invention, the oxidation solution and/or passivation solution isrinsed off the coated base metal after the formation of the passivationlayer. In still yet another embodiment of the present invention, thepacified intermetallic layer exhibits excellent formabilitycharacteristics. The formability of the base material having a pacifiedintermetallic layer on the surface of the base material exhibitsimproved formability characteristics over a tin metal alloy or a tin andzinc metal alloy coated base material. The improved formability isbelieved to be the result of the complete or partial removal of the tinmetal alloy or tin and zinc metal alloy from the surface of the basematerial. The removal of the tin metal alloy or tin and zinc metal alloyreduces the thickness of the treated base material. The tin metal alloyor tin and zinc metal alloy is also less formable than many types ofbase metal such as, but not limited to, copper, copper alloys, aluminum,aluminum alloys. As a result, the reducing of the thickness of thecoated base material and by partial or complete removal of a lessformable metal layer, i.e. the tin metal alloy or tin and zinc metalalloy, results in formability. In yet another embodiment of theinvention, the thickness of the passivation layer is at least about 0.1micron. In still another embodiment of the invention, the thickness ofthe passivation layer is about 0.1-5 microns. In still anotherembodiment of the invention, the thickness of the passivation layer isup to about 1.5 microns.

[0077] In accordance with still another aspect of the present invention,the coated base metal is treated with a weathering agent to acceleratethe weathering, discoloration of the surface of the metal alloy coating,and/or control the formation of white rust on the surface of the metalalloy coating. In one embodiment of the invention, the weatheringmaterial is applied to the metal alloy coating to oxidize the metalalloy coating surface, reduce the reflectivity of the metal alloycoating, and/or discolor the metal alloy coating. In another embodimentof the invention, the weathering material is an asphalt-based paintwhich causes accelerated weathering of the metal alloy coating whenexposed to the atmosphere. The asphalt-based paint decreases theweathering time of the metal alloy coating. In one aspect of thisembodiment, the asphalt paint is a petroleum-based paint which includesasphalt, titanium oxide, inert silicates, clay, carbon black or otherfree carbon and an anti-settling agent. In another aspect of thisembodiment, the asphalt-based paint is applied at a thickness to form asemi-transparent or translucent layer over the metal alloy coating. Inone specific aspect, the thickness of the asphalt-based paint is about1-500 microns. In another specific aspect, the thickness of theasphalt-based paint is about 6-150 microns. In still another specificaspect, the thickness of the asphalt-based paint is about 6-123 microns.In yet another specific aspect, the thickness of the asphalt-based paintis about 12-50 microns. In still yet a further specific aspect, thethickness of the asphalt-based paint is about 12-25 microns. In stillyet another embodiment of the invention, the weathering agent is driedby air drying and/or by heating lamps.

[0078] In accordance with yet another aspect of the present invention,the metal alloy or base metal coated with the metal alloy coating isimmediately formed, or formed at a manufacturing site, or formed at abuilding site. In one embodiment of the invention, the metal alloy orcoated base metal is formed into roofing materials such as disclosed in,but not limited to, gutter systems or roofing material which areillustrated in U.S. Pat. Nos. 4,987,716; 5001,881; 5,022,203; 5,259,166;and 5,301,474, all of which are incorporated herein by reference. In oneaspect of this embodiment, the roofing materials are formed on site. Inanother embodiment of the invention, the metal alloy or coated basemetal is formed into an automotive part such as, but not limited to agasoline tank. In one aspect of this embodiment, the gasoline tankincludes a first and second metal shell member. The two combinedcavities of the shell members are combined to form an inner fuelreceiving chamber which holds fuel within the receptacle. The abuttingperipheral edges of the shell members are joined together and sealed tomaintain the fuel within the inner petroleum receiving chamber. The twoshell members may be joined in any of a number of ways that willsecurely prevent the shells from separating and petroleum from leakingfrom the interior chamber (i.e. welding, soldering and/or bonding theedges together). Such a fuel tank is illustrated in U.S. Pat. No.5,455,122, which is incorporated herein by reference. In still anotherembodiment of the invention, the metal alloy is formed into a wire. Inone aspect of this embodiment, the wire is used as a solder or weldingwire to solder or weld together metals. In one specific aspect, thesolder or welding wire is formulated to have excellent wettingproperties which helps to ensure the formation of a high quality bondbetween metal materials. In another specific aspect, the solder orwelding wire is formulated to have a low lead content. In still anotherspecific aspect, the solder or welding wire can be used in standardsoldering guns or welding apparatuses (i.e. ultrasonic welding, arcwelding, gas welding, laser welding). In still yet another specificaspect, the solder has low dissolving activity with the welded metalmaterials. In a further specific aspect, the welding wire is a solidwelding wire or a cored welding wire. In still another embodiment of theinvention, the metal alloy exhibits excellent soldering or weldingcharacteristics such that various electrodes including lead and/orno-lead containing solders and/or electrodes can be used to solderand/or weld the metal alloy or coated base metal.

[0079] In accordance with yet another aspect of the present invention,the metal alloy and/or coated base metal base material can be formed onsite without the metal alloy cracking and/or flaking off.

[0080] In accordance with still another aspect of the present invention,the metal alloy is formed into a corrosion-resistant strip or sheet. Inone embodiment of the invention, the metal alloy strip is formed by aroll forming process. In the roll forming process, a vat of molten metalalloy is provided. The molten alloy is then directed through a series ofrollers until the desired thickness of the metal alloy strip or sheet isobtained.

[0081] The primary object of the present invention is the provision of ametal alloy having corrosion-resistant properties.

[0082] Another object of the present invention is the provision of abase metal coated with a metal alloy having corrosion resistantproperties.

[0083] Yet another object of the present invention is the provision of ametal material at least partially formed from a metal alloy havingcorrosion resistant properties.

[0084] Still another object of the present invention is the provision ofa metal alloy and/or coated base metal which is both corrosion-resistantand environmentally-friendly.

[0085] Still yet another object of the present invention is theprovision of a coated base metal having a sufficient coating thicknessto reduce or eliminate pinholes in the coating and/or which the shearingof the coating is inhibited when the coated base metal is formed.

[0086] Another object of the present invention is the provision of acoated base metal having a heat created intermetallic layer formedbetween the base metal and the metal alloy coating.

[0087] Yet another object of the present invention is the provision of acoated base metal coated by a hot dip process.

[0088] Still another object of the present invention is the provision ofcoating a base metal by a plating process.

[0089] Yet still another object of the present invention is theprovision of a base metal coated by a continuous process.

[0090] Still yet another object of the present invention is theprovision of a metal alloy or a coated base metal which is formed andsheared into various building and roofing components, automotivecomponents, marine products, household materials, and other formedmaterials that are subsequently assembled on site or in a formingfacility.

[0091] Another object of the present invention is the provision of ametal alloy or coated base metal that is corrosion-resistant and whichcan be formed into complex shapes and/or ornamental designs.

[0092] Another object of the present invention is the provision of acorrosion resistant metal alloy which includes a coloring agent to alterthe color of the corrosion resistant metal alloy, a corrosion-resistanceagent to improve the corrosion-resistance of the corrosion resistantmetal alloy, a mechanical agent to improve the mechanical properties ofthe corrosion resistant metal alloy, a grain agent to positively affectgrain refinement of the corrosion resistant metal alloy, an oxidationagent to reduce oxidation of the molten corrosion resistant metal alloy,an inhibiting agent to inhibit the crystallization of the corrosionresistant metal alloy, and/or a bonding agent to improve the bondingcharacteristics of the corrosion resistant metal alloy.

[0093] Still another object of the present invention is the provision ofa corrosion resistant metal alloy which includes a majority of tin.

[0094] Yet another object of the present invention is the provision of acorrosion resistant metal alloy which includes a majority of tin andzinc.

[0095] Another object of the present invention is the provision ofapplying an intermediate barrier metal layer to the surface of the basemetal prior to applying the corrosion resistant metal alloy coating.

[0096] Still another object of the present invention is the provision ofa coated base metal or metal alloy which is formed into wire, wiresolder and/or welding electrodes.

[0097] Still yet another object of the invention is the provision of ametal alloy and/or a coated base metal which is economical to produce.

[0098] Another object of the invention is the provision of a metal alloyand/or a coated base metal that can be soldered with conventionaltin-lead solders or no-lead solders.

[0099] Yet another object of the present invention is the provision ofpretreating the base metal prior to coating the base metal with acorrosion resistant alloy to remove oxides and/or foreign materials fromthe surface of the base metal.

[0100] Another object of the present invention is the provision ofpickling the base metal to remove surface oxides on the base metal priorto coating the base metal with a metal alloy.

[0101] Yet another object of the present invention is the provision ofchemically activating the base metal to remove surface oxides on thebase metal prior to coating the base metal with a metal.

[0102] Still yet another object of the present invention is theprovision of reducing the oxygen interaction with the base metal priorto and/or during the coating process.

[0103] Another object of the present invention is the provision ofabrasively treating the surface of the base metal prior to coating thebase metal with a metal alloy.

[0104] Still yet another object of the present invention is theprovision of a metal alloy and/or a metal coating that is not highlyreflective.

[0105] Yet another object of the present invention is the provision of ametal alloy and/or a metal coating for a base metal which has a low leadcontent.

[0106] Still yet another object of the present invention is theprovision of using spray jets to spray molten metal alloy onto thesurface of the base metal to coat the surface of the base metal.

[0107] Another object of the present invention is the provision ofcoating a metal alloy and/or a metal coating with a weathering agent toaccelerate the dulling of the surface of the metal alloy.

[0108] Still another object of the present invention is the use of anair-knife process to control the thickness and quality of the metalalloy coating on the base metal.

[0109] Yet still another object of the present invention is theprovision of cooling the metal alloy and/or a metal coating to formfine, high density grains which produce a strong bonding,corrosive-resistant, discolored coating.

[0110] Another object of the present invention is the provision ofsubjecting the coated base metal to an oxidation solution to at leastpartially remove the metal alloy from the base metal and to at leastpartially expose the heat created intermetallic layer.

[0111] Still another object of the present invention is the provision ofsubjecting the heat created intermetallic layer to a passivationsolution to form a highly corrosion-resistant, non-reflective surfacelayer on the base metal.

[0112] Still yet another object of the present invention is theprovision of a metal alloy coating which has superior corrosivecharacteristics permitting a thinner coating of the metal alloy to thebase metal than that which is required for conventional terne coatingswith the high lead content.

[0113] Still yet another object of the present invention is theprovision of using spray jets which spray metal alloy onto the coatingrollers and/or base metal surface to eliminate non-coated surfaces onthe base metal. Another object of the present invention is the indirectheating of the melting pot without use of heating coils or heating rods.

[0114] Another object of the present invention is the provision of acorrosion resistant metal alloy that can be coated on a number ofdifferent base metal compositions.

[0115] Yet another object of the present invention is the provision of acorrosion resistant metal alloy that can be coated a base metal having anumber of different shapes.

[0116] Still another object of the present invention is the provision ofproviding a coated base metal which is formed by a continuous, hot dipprocess wherein the base metal has a controlled residence time whenexposed to the molten metal alloy.

[0117] Still yet another object of the present invention is theprovision of producing a highly corrosion-resistant metal alloy orcoated base material that is economical to make.

[0118] These and other objects and advantages will become apparent tothose skilled in the art upon the reading and following of thisdescription taken together with the accompanied drawing.

BRIEF DESCRIPTION OF THE DRAWINGS

[0119] Reference may now be made to the drawings, which illustratevarious embodiments that the invention may take in physical form and incertain parts and arrangements of parts wherein;

[0120] FIGS. 1A-1B is a cross-sectional view of a hot dip processwherein a metal strip is coated with a corrosion resistant alloy byimmersing the metal strip in molten corrosion resistant metal alloy;

[0121]FIG. 2 is a cross-section view of additional and/or alternativeprocesses for handling the coated metal strip;

[0122]FIG. 3 is a cross-sectional view of the process of plating a metalstrip with a corrosion resistant metal alloy;

[0123]FIG. 4 illustrates a cross-sectional view of the process of flowheating the plated metal alloy;

[0124]FIG. 5 illustrates a cross-section view of an alternative processof cooling the hot-dip coated base metal in a cooling tank;

[0125]FIG. 6 illustrates a cross-sectional view of an alternativeprocess of using metal spray jets during the hot-dip coating process tocoat the metal strip;

[0126]FIG. 7 illustrates a cross-sectional view of an alternativeprocess of using an air-knife during the hot-dip coating process tocontrol the thickness of the coating on the metal strip;

[0127]FIG. 8 illustrates a cross-sectional view of an alternativeprocess of cooling the hot-dip metal alloy coated base metal by sprayjets;

[0128]FIG. 9 illustrates a cross-sectional view of an alternativeprocess of using abrasion treaters in conjunction with a low oxygenenvironment to pre-treat the base metal;

[0129]FIG. 10 is a frontal view of a camel-back guide;

[0130]FIG. 11 is a prospective view of a melting pot heated by gastorches;

[0131]FIG. 12 is a cross-sectional view of a coated metal strip having aheat-created intermetallic layer;

[0132]FIG. 13 illustrates a cross-sectional view of an alternativeprocess of using an oxidation process and rinse process to at leastpartially remove the metal alloy coating from the base metal to at leastpartially expose the heat created intermetallic layer;

[0133]FIG. 14 is a cross-sectional view of a coated metal strip having aheat-created intermetallic layer and passivated surface layer.

[0134]FIG. 15 illustrates a cross-sectional view of an alternativeprocess of coating a base metal by a hot dip process wherein a basemetal strip is unrolled and coated by immersing the metal strip in amolten pot of molten alloy and then subjecting the metal strip tocoating rollers and an air-knife process and then rolling the coatedmetal strip into a coil;

[0135]FIG. 16 is a plane view of a gasoline tank formed from the metalalloy or base metal coated with the metal alloy of the presentinvention;

[0136]FIG. 17 illustrates the joining of the first and second shellmembers of the gasoline tank at the peripheral edges;

[0137]FIG. 18 is a partial cross-sectional view of a gasoline tankillustrating a corrosion resistant coating on the metal shell after acoated base metal shell has been drawn;

[0138]FIG. 19 is a perspective view of a pair of adjacent roofing panelsformed from the metal alloy or base metal coated with the alloy of thepresent invention;

[0139]FIG. 20 is a cross-sectional view showing the initial assembly ofthe roofing panels of FIG. 19; and

[0140]FIG. 21 is a cross-sectional view of the process of roll formingthe metal alloy of the present invention into a metal alloy strip.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0141] Referring now to the drawings, wherein the showings are for thepurpose of illustrating preferred embodiments of the invention only andnot for the purpose of limiting the same, reference is first had toFIGS. 1A-1B which illustrates one type of hot-dip process for coating ametal alloy on a base metal and forming a heat created intermetalliclayer between the metal alloy coating and the base metal. However, aswill be later discussed, the base metal can be alternatively coated by aprocess that does not form a heat created intermetallic layer betweenthe metal strip and metal alloy coating. The base metal and process usedto coat and/or pre-treat the base metal are illustrated in FIGS. 1-15.The base metal is in the form of a metal strip; however, other forms ofthe base metal can be used (i.e. metal plates, metal strip or metalplate formed into various shapes, various shaped metal objects) and becoated with a metal alloy in accordance with the present invention.

[0142] The metal alloy is a corrosion resistant alloy. When the metalalloy is coated onto the surface of a base metal, the metal alloyinhibits or prevent the base metal from corroding when exposed to theatmosphere. The metal alloy is highly corrosive resistant, abrasiveresistant, pliable, weldable and environmentally friendly. The metalalloy binds with the base metal to form a durable protective coatingwhich is not easily removable.

[0143] The amount of corrosion resistance protection provided by themetal alloy is of primary importance. The coating of the metal stripwith the metal alloy functions to form a barrier to the atmosphere whichinhibits or prevents the metal strip from corroding. By coating themetal strip with the metal alloy, the life of the metal strip isextended for many years. The pliability of the metal alloy is alsoimportant when the coated metal strip is to be formed. For materialssuch as, but not limited to, wall systems, roofing systems and petroleumreceptacles, the coated base metal is formed into various shapes and isusually folded to form seams to bind together the coated base metalcomponents. A coating on a metal strip that forms a rigid or brittlecoating can crack and/or prevent the coated base metal components frombeing properly shaped. The metal alloy is formulated to be connectedtogether by solder or a weld.

[0144] Metal strips, such as, but not limited to, carbon steel,stainless steel, copper, copper alloys, aluminum and aluminum alloys,oxidize when exposed to the atmosphere and/or various types of chemicalsor petroleum products. Over a period of time, the oxidized metal stripbegins to weaken and disintegrate. The application of a corrosionresistant metal alloy onto the metal strip acts as a barrier to theatmosphere and/or chemical or petroleum products to inhibit or preventthe oxidation of the metal strip. By coating the metal strip with thecorrosion resistant metal alloy, the life of the metal strip is extendedfor many years.

[0145] As illustrated in FIGS. 1A-1B, metal strip 12 is provided from alarge metal roll 10. Metal strip 12 has a thickness of less than about12700 microns, and typically about 127-5080 microns; however, othermetal strip thickness can be used depending on the type of base metaland the use of the coated base metal. Metal strip 12 is unwound fromroll 10 at speeds which are generally less than about 400 ft./min.,typically about 1-150 feet, more typically about 70-250 ft./min., andyet more typically about 50-115 ft/min. The metal strip speed isultimately selected so that the residence time of the metal strip incontact with the molten metal alloy is sufficient to coat the desiredamount of strip to a desired thickness and to form a heat createdintermetallic layer of a desired thickness.

[0146] After metal strip 12 is unrolled from metal roll 10, metal strip12 is optionally pretreated prior to being coated with the metal alloy.As illustrated in FIGS. 1A-1B, metal strip 12 is pretreated to cleanand/or remove surface oxides from the surface of the metal strip priorto the metal strip being coated with the corrosion resistant metalalloy. The type and number of pretreatment process for metal strip 12will depend on the surface condition of the metal strip.

[0147] Metal strip 12 is illustrated in FIGS. 1A and 9 as being cleanedby an abrasion treater 14 after being unrolled from metal roll 10. Theabrasion treater includes brushes 16 that are driven by motors. Thebrushes are placed in contact with metal strip 12 to remove foreignobjects from metal strip 12 and to initially etch and/or mechanicallyremove oxides from the surface of metal strip 12. Brushes 16 aretypically biased against metal strip 12 to cause friction between thebrushes and metal strip 12, which friction facilitates in the cleaningof the surface of metal strip 12. Typically, brushes 16 are located onthe top and bottom surface of strip 12. As can be appreciated, thebrushes can be positioned to only contact a portion of the surface ofthe metal strip. Brushes 16 are typically made of a material having ahardness equal to or greater than metal strip 12 so that the brusheswill not quickly wear down when removing foreign materials and/orpre-etching the surface of metal strip 12. In one arrangement, thebrushes are made of a metal material such as, but not limited to, carbonsteel wire brushes. Brushes 16 typically rotate in a direction that isopposite of the direction of the moving metal strip. This oppositerotational direction of the brushes causes increased abrasive contactwith the surface of the metal strip. The abrasion treatment of the metalstrip surface can also include the use of absorbents, cleaners and/orsolvents. These absorbents, cleaners and/or solvents can be applied topart of or to the full surface of metal strip 12 before, during and/orafter metal strip 12 is treated with brushes 16. The cleaners and/orsolvents can include, but are not limited to, alkaline cleaners, acidiccleaners and/or organic solvents.

[0148] After metal strip 12 passes through abrasion treater 14, metalstrip 12 is guided by strip guides 13 to a low oxygen environment 20. Asshown in FIGS. 1A and 9, strip guides 13 are positioned throughout thepretreatment and coating processes to guide metal strip 12 through eachprocess. Low oxygen environment 20 is illustrated as being a low oxygengas environment that fully surrounds the surface of metal strip 12 withlow oxygen-containing gas 22. As can be appreciated, the low oxygen gasenvironment can be designed to only partially protect one or moresurfaces of metal strip 12. The low oxygen-containing gas includes, butare not limited to, nitrogen, hydrocarbons, hydrogen, noble gases and/orother non-oxygen containing gases. The low oxygen-containing gassurrounds metal strip 12 and forms a barrier against the oxygencontaining atmosphere thereby preventing or inhibiting oxide formationon the surface of metal strip 12. As can be appreciated, low oxygenenvironment 20 can include or in the alternative be a low oxygen liquidenvironment. In a low oxygen liquid environment, the liquid can besprayed on to one or more surfaces of the metal strip or the metal stripcan be partially or fully immersed in the low oxygen-containing liquid.

[0149] Metal strip 12, after passing through low oxygen gas environment20, enters pickling tank 30 which contains a pickling solution 32. Thepickling solution is formulated to remove surface oxides from the metalstrip surface, remove dirt and other foreign materials from the metalstrip surface and/or etch the surface of the metal strip. Pickling tank30 is of sufficient length and depth to allow for complete immersion ofmetal strip 12 in pickling solution 32 and to maintain the metal stripin contact with the pickling solution for a sufficient period of time.Typically, pickling tank 30 is at least about 25 feet in length. As canbe appreciated, the pickling tank can be longer or shorter depending onthe speed of the metal strip. Furthermore, the pickling tank can bedesigned so that only a portion of the surface of metal strip 12contacts the pickling solution. The pickling solution typically containsone or more acids. The acids include organic and/or inorganic acids.Such acids include, but are not limited to, perchloric acid,hydrofluoric acid, sulfuric acid, nitric acid, hydrochloric acid,phosphoric acid, and/or isobromic acid. Typically, pickling solution 32includes hydrochloric acid. Generally, the pickling solution contains atleast about 5% by volume hydrochloric acid. For metal strip havingextensive surface oxides and/or difficult to remove surface oxides, suchas stainless steel strip, an aggressive pickling solution is used. Onetype of aggressive pickling solution is a dual acid solution ofhydrochloric acid and nitric acid. Formulations of thehydrochloric-nitric acid include a) about 1-30% by volume hydrochloricacid and about 0.1-15% by volume nitric acid, b) about 5-25% by volumehydrochloric acid and 1-15% by volume nitric acid, and c) about 10%hydrochloric acid and 3% nitric acid. Pickling solution 32 is maintainedat a temperature to obtain the desired activity of the picklingsolution. Typically, pickling solution 32 is maintained at a temperatureof at least about 26° C., generally about 48-60° C., and typically about53-56° C. Pickling tank 30 contains one or more agitators 34. Agitator34 is designed to agitate pickling solution 32 to maintain a uniformsolution concentration, maintain a uniform solution temperature and/orbreak up gas pockets which form on the surface of metal strip 12.Agitator 34 typically includes an abrasive material which can bothagitate pickling solution 32 and remove of oxides from metal strip 12when in contact with the surface of the metal strip. Agitator 34 istypically made of a material which does not react with pickling solution32 and resists undue wear when in contact with the metal strip surface.Metal strip 12 is typically not exposed to the pickling solution formore than about 10 minutes so as to avoid pitting of the metal stripsurface; however, longer pickling times can be used depending on thetype of pickling solution, concentration and temperature of the picklingsolution, type of metal strip, and/or condition of metal strip surface.Typically, the pickling time is less than about ten minutes, moretypically less than about two minutes, still more typically less thanabout one minute, and yet more typically about 10-20 seconds. A picklingsolution vent 36 is placed above pickling tank 30 to collect and removeacid fumes and other gasses escaping pickling tank 30.

[0150] As illustrated in FIG. 1A, metal strip 12 enters a low oxygenenvironment 20 after exiting pickling tank 30. After metal strip 12exits pickling tank 30, the surface of metal strip 12 is essentiallyabsent surface oxides and other foreign materials and is highlysusceptible to oxidation with oxygen and other gases in the atmosphere.Low oxygen environment 20 shields the surface of metal strip 12 fromoxygen and other oxidizing gases and/or liquids thereby inhibiting oxideformation on the metal strip surface. Low oxygen environment 20 is a lowoxygen-containing gas environment similar to the low oxygen environmentused after the abrasion treatment process; however, a lowoxygen-containing liquid environment could be used in conjunction withor as an alternative to the low oxygen-containing gas environment.

[0151] After metal strip 12 exits low oxygen environment 20, metal strip12 enters rinse tank 40 which contains a rinse solution 42. Rinse tank40 is designed to remove any remaining pickling solution 32 on thesurface of metal strip 12 and/or inhibit the formation of oxides on themetal strip surface. One type of rinse solution includes water that isdeoxygenated by heating the water above about 100-110° F. As can beappreciated, other rinse liquids can be used. Rinse solution 42 canremove small amounts of oxides that remain on the surface of metal strip12. The rinse solution typically is slightly acidic due to the acidicpickling solution that is removed from the metal strip surface. As canbe appreciated, the rinse solution can be also acidified by theintentional addition of acid to the rinse solution. The slightly acidicrinse solution 42 removes small amounts of oxides on the surface ofmetal strip 12. Rinse tank 40 is of sufficient length and depth tofacilitate complete immersion of metal strip 12 in rinse solution 42 andto maintain the metal strip in contact with the rinse solution for asufficient period of time. Typically, rinse tank 40 is at least about 20feet in length. As can be appreciated, the rinse tank can be longer orshorter depending on the speed of the metal strip. Furthermore, therinse tank can be designed so that only a portion of the surface ofmetal strip 12 contacts the rinse solution. The rinse tank typicallyincludes one or more agitators, not shown. The agitators are designed toagitate rinse solution 42 to maintain a uniform solution concentration,maintain a uniform solution temperature, and/or break up gas pocketswhich form on the surface of metal strip 12. The agitators typicallyinclude an abrasive material which can both agitate the rinse solutionand remove remaining oxides on the surface of metal strip 12 when incontact with the surface of the metal strip. The agitators are typicallymade of a material which does not react with rinse solution 42 andresists undue wear when in contact with the metal strip surface. As canbe appreciated, the pickling solution can be alternatively or inconjunction be removed by spraying a rinse fluid onto a portion or thefull surface of metal strip 12.

[0152] Referring now to FIG. 11B, metal strip 12 enters low oxygenenvironment 50 after exiting rinse tank 40. Low oxygen environment 50 isa low oxygen-containing liquid environment which includes spray jets 52.Spray jets 52 are located on each side of metal strip 12 so as to directthe low oxygen-containing liquid onto both sides of metal strip 12. Ascan be appreciated, the spray jets can be positioned about metal strip12 so that only a portion of the strip surface is subjected to the lowoxygen-containing liquid. The low oxygen-containing liquid 56 inhibitsoxide formation of the metal strip surface. Spray jets 52 also removeremaining pickling solution 32 or other acid on the surface of metalstrip 12. Low oxygen-containing liquid 56 is typically heated waterhaving a temperature of at least about 38-43° C. As can be appreciated,other low oxygen-containing liquids can be used. Furthermore, it can beappreciated that low oxygen environment 50 can include or in thealternative be a low oxygen-containing gas environment.

[0153] Metal strip 12, upon leaving low oxygen liquid environment 50,enters chemical activation tank 60 which includes a chemical activatingsolution or deoxidizing solution 62. The chemical activation tank is ofsufficient length and depth to facilitate complete immersion of metalstrip 12 in deoxidizing solution 62 and to maintain the metal strip incontact with the deoxidizing solution for a sufficient period of time.Typically, chemical activation tank is at least about 25 feet in length.As can be appreciated, the chemical activation tank can be longer orshorter depending on the speed of the metal strip. Furthermore, thechemical activation tank can be designed so that only a portion of thesurface of metal strip 12 contacts the deoxidizing solution. Thechemical activation tank typically includes one or more agitators, notshown. The agitators are designed to agitate deoxidizing solution 62 tomaintain a uniform solution concentration, maintain a uniform solutiontemperature and/or break up gas pockets which form on the surface ofmetal strip 12. The agitators typically include an abrasive materialwhich can both agitate the deoxidizing solution and remove any remainingoxides on the surface of metal strip 12 when in contact with the surfaceof the metal strip. The agitators are typically made of a material whichdoes not react with deoxidation solution and resists undue wear when incontact with the metal strip surface. The metal strip is generallysubjected to the deoxidizing solution for less than about 10 minutes,and typically less than about one minute; however, longer times can beused. Deoxidizing solution 62 is formulated to remove remaining oxideson the surface of metal strip 12 and/or act as a protective coating toinhibit oxide formation on the surface of metal strip 12. Thetemperature of the deoxidizing solution is maintained at a temperatureto achieve sufficient activity of the deoxidizing solution. Typically,the temperature of the deoxidizing solution is maintained at least about15° C., typically about 15-33° C., and more typically about 26-33° C.The deoxidizing solution typically includes zinc chloride; however,other chemical compounds can be used. Small amounts of an acid can beadd to the deoxidizing solution to further enhance oxide removal fromthe metal strip surface. One specific deoxidizing solution formulationincludes at least about 1% by volume zinc chloride. Another specificdeoxidizing solution formulation includes about 5-50% by volume zincchloride. Yet another specific deoxidizing solution formulation includesabout 5-50% by volume zinc chloride and about 0.5-15% by volumehydrochloric acid.

[0154] After metal strip 12 exits chemical activation tank 60, metalstrip 12 enter the final pretreatment step of immersion in a fluxsolution 74 contained in flux box 72. As can be appreciated, metal strip12 can be exposed to a low oxygen environment, not shown, prior toentering flux solution 74 to inhibit or prevent oxide formation on themetal strip surface after the metal strip exits chemical activation tank60. As also can be appreciated, flux box 72 can be designed so that onlya portion of metal strip 12 is exposed to flux solution 74. Flux box 72is located in melting pot 70. The flux solution in flux box 72 has aspecific gravity that is less than or equal to the specific gravity ofmolten corrosion resistant metal alloy 76 so that flux solution 74 atleast partially floats on the surface of the molten corrosion resistantmetal alloy. Flux solution 74 typically includes zinc chloride andammonium chloride; however, other compounds can be used. Specificformulations of flux solution 74 include a) about 20-75% by volume zincchloride and 1-40% by volume ammonium chloride, b) about 20-75% byvolume zinc chloride and 1-20% by volume ammonium chloride, c) about30-60 weight percent zinc chloride and up to about 40 weight percentammonium chloride, d) about 30-60 weight percent zinc chloride and about5-40 weight percent ammonium chloride, and e) about 50 weight percentzinc chloride and about 8 weight percent ammonium chloride. As can beappreciated, other concentrations of these two components can be used.Flux solution 74 is the final pre-treating process of metal strip 12 forremoval of remaining oxides on the surface of metal strip 12 prior tobeing coated with metal alloy 76. Flux box 74 also acts as a barrier tooxygen and prevents or inhibits oxides from forming on the surface ofthe metal strip and on the surface of the molten metal alloy covered bythe flux solution.

[0155] An additional or alternative pretreatment process is the coatingof metal strip 12 with an intermediate barrier metal layer prior tocoating the metal strip with the corrosion resistant metal alloy. Thecoating of the metal strip with an intermediate barrier metal layer canconstitute the only pretreatment process for the metal strip, or themetal strip can be pretreated with one or more other pretreatmentprocess before and/or after the metal strip is coated with anintermediate barrier metal layer. The intermediate barrier metal layeris typically a thin layer of metal such as, but not limited to, tin,nickel, copper, chromium, aluminum, cobalt, molybdenum, Sn—Ni, Fe—Ni,and/or zinc. The thickness of the layer is generally less than about 500microns and typically less than about 100 microns. The intermediatebarrier metal layer can be applied by an electroplating process, anelectroplating process and subsequent heating of the, plated layer,immersion in molten metal, metal spraying, coating rollers, and thelike. The process for plating the intermediate barrier metal layer ontothe surface of metal strip 12 is typically by a conventional continuousplating process. The applied intermediate barrier metal layer typicallyforms a strong bond with the metal strip, whether or not the stripsurface has been activated. The bonding of the intermediate barriermetal layer to the strip is enhanced by heating the intermediate barriermetal layer and the forming a heat created intermetallic layer betweenthe metal strip and the intermediate barrier metal layer. When theintermediate barrier metal layer is plated and then flow heated, thethickness of the intermediate barrier metal layer is typically at leastabout 2 microns so that a sufficiently thick intermediate barrier metallayer exists for proper flow heating. The selection of metal of theintermediate barrier metal layer can advantageously change thecomposition of the heat created intermetallic layer thereby improvingcorrosion resistance, improving metal alloy bonding, improve metal alloypliability, and/or inhibiting the formation of a thick zinc layer in theintermetallic layer when zinc is included in the metal alloy.

[0156] Another additional or alternative pretreatment process is thepreheating of the metal strip prior to coating the metal strip with thecorrosion resistant metal alloy. Metal strip that has a thickness ofless than about 762 microns is typically not pre-heated. Thicker metalstrip can be preheated to assist in the formation of the heat createdintermetallic layer. A thin metal strip need not be preheated since thesurface of the thin strip quickly heats to the temperature of the moltenmetal alloy. As the surface of the metal strip approaches thetemperature of the molten metal alloy, an intermetallic layer begins toform between the surface of the metal strip and the metal alloy coating.Metal strip having a thickness of up to about 762 microns is classifiedas thin metal strip. However, thin metal strip can be preheated and suchpreheated strip forms an intermetallic layer quicker than a nonpre-heated strip. Metal strip having a thickness over about 762 micronsis classified as a thick metal strip. Thick metal strip is preferablypreheated prior to coating with the metal alloy. The surface of a thickmetal strip takes a longer time to approach the temperature of themolten metal alloy due to the larger heat sink of the thicker metalstrip. Preheating the thick metal strip facilitates in the surface ofthe metal strip reaching or approaching the molten temperature of themetal alloy during the coating process so that a desired heat createdintermetallic layer is formed. Metal strip 12 can be preheated in anynumber of ways, such as but not limited to, convection or inductionheating, flames, lasers, and the like. When a heat created intermetalliclayer is not to be formed, the meal strip is typically not pre-heated.

[0157] Although FIGS. 1A-1B illustrate metal strip 12 being pretreatedby the pretreatment processes of abrasion, pickling and rinsing,chemical activation, exposure to low oxygen environment, and the fluxsolution, the use of all these pretreatment process on all types ofmetal strip is not always required. When the metal strip has a cleansurface and/or little or no oxide formation on the metal strip surface,the pretreatment process can be eliminated or only a select number ofpretreatment processes can be used prior to coating the metal strip withthe corrosion resistant metal alloy.

[0158] Referring to FIG. 1B, metal strip 12, after exiting flux box 72,enters molten corrosion resistant metal alloy 76. Melting pot 70 istypically heated by heating jets, coils, rods, heat exchangers, etc. Inone particular arrangement, melting pot 70 is heated by four heatingjets 71 directed at the outside sides of melting pot 70 as shown in FIG.11. The heating jets are typically gas jets. Melting pot 70 ismaintained at a temperature of at least several degrees above themelting point of corrosion resistant metal alloy 76 to preventsolidification of metal alloy 76 as metal strip 12 enters melting pot70. Tin melts at about 232° C. (450° F.). Zinc melts at about 419.6° C.(787° F.). When additives and/or impurities are included in the tinmetal alloy or tin and zinc metal alloy, the melting point of metalalloy 76 will be altered. The composition and/or thickness of meltingpot 70 is altered to accommodate the various alloy melting temperatures.The temperature of the molten can be up to or more than 38° C. cooler atthe top of the melting pot than at the bottom of the melting pot.Typically, the tin metal alloy or tin and zinc metal alloy is maintainedat least about 2-30° C. above the melting point of the metal alloy atthe top of the melting pot. The temperature of the molten metal alloy ismaintained at a sufficient level to prevent solidification of the moltenmetal when strip 12 enters the molten metal. The temperature of themetal alloy in the melting pot is selected to accommodate the inclusionof additives and/or impurities in metal alloy 76. Generally, thetemperature of the molten metal alloy in the melting pot is about231-538° C. For high melting point metal alloys, additional heating jetsor other additional heating devices can be used to heat the metal alloyin the melting pot to the desired temperature.

[0159] The molten metal alloy in the melting pot is generally formed byadding ingots of tin for a tin alloy coating and ingots of tin andingots of zinc for a tin and zinc metal alloy coating into the meltingpot wherein the ingots are melted and mixed. The ingots may contain someadditional elements which function as additives or impurities in the tinmetal alloy or tin and zinc metal alloy. The amount of impurities in themetal alloy are controlled so as to reduce the adverse affects of suchimpurities.

[0160] As shown in FIG. 1B, melting pot 70 is divided into two chambersby barrier 80. Barrier 80 is designed to prevent protective material 78,such as palm oil, from spreading over the complete top surface of moltencorrosion resistant alloy 76 in melting pot 70. As can be appreciated,barrier 80 can be eliminated. When the protective material is palm oil,the melting point of the metal alloy should be below the 343° C. so asto not degrade the palm oil. For metal alloys having higher meltingpoint temperatures, special oils, fluxes, or other materials and/orspecial cooling procedures are employed when a protective material isused. Protective material 78 has a specific gravity which enables theprotective material to at least partially float on the surface of moltenalloy 76. The protective material inhibits or prevents the surface ofmolten metal alloy from solidifying by insulating the surface from theatmosphere, inhibits or prevents the surface of molten metal alloy fromoxidizing, and/or aids in the properly distribution the metal alloy onthe surface of metal strip 12 upon exiting the molten metal alloy.

[0161] Melting pot 70 is generally about 10-100 ft. in length so as toprovide an adequate residence time for the metal strip in the moltenmetal alloy as the metal strip moves through the molten metal alloy 76in the melting pot. Longer melting pot lengths can be employed for fastmoving metal strip. The residence time of the metal strip in the moltenmetal alloy is sufficiently long enough to form the desired thickness ofheat created intermetallic layer 140. The residence time of metal strip12 in melting pot 70 is generally at least about 5 seconds and less thanabout 10 minutes, typically less than about 2-10 minutes, more typicallyless than about one minute, still more typically about 5-30 seconds, andeven more typically about 10-30 seconds. When the metal strip is coatedwith the metal alloy by a continuous immersion process, the metal stripis typically moved through the molten tin alloy in the melting pot in acurvilinear path; however, other paths can be used. When the metal stripuses a curvilinear path, the metal strip requires fewer, if any, guiderolls (driving rollers), especially when the metal strip is made of amore malleable material such as, but not limited to, copper. Thecurvilinear path of the metal strip allows the metal strip to dictateits path in the molten metal alloy. The coating thickness of the metalalloy onto the metal strip is a function of the time the metal strip isresident or immersed in the molten tin alloy. The coating thicknessincreases the longer the metal strip is maintained in the molten metalalloy. In a continuous immersion coating process, the resident time ofthe surfaces of the metal strip in the molten metal alloy issubstantially the same. The uniformity of residence time in the moltenmetal alloy results in a more uniform coating thicknesses on the surfaceof the metal strip and substantially uniform growth of the heat createdintermetallic layer. The metal strip is typically maintained at aconstant speed through the molten metal alloy to create a more smoothcoated surface. As the metal strip passes through the molten metal alloyat a substantially constant speed, the molten metal alloy about themetal strip adheres to the moving metal strip and shears a portion ofthe coating from the moving metal strip. This shearing effect resultsfrom the viscosity of the molten metal alloy and the speed at which themetal strip is moving through the molten metal alloy. For a given speedand molten metal alloy viscosity, a constant shearing effect is appliedto the surface of the moving metal strip thereby smoothing the coatedsurface and facilitating in the formation of a constant coatingthickness. By using a continuous coating process to coat the metal stripwith a metal alloy, a uniform of coating (weight and thickness) isobtained, having excellent surface appearance, smoothness, texturecontrol and a substantially uniform heat created intermetallic layer.

[0162] During the coating of the metal strip with molten metal alloy, aheat created intermetallic layer 140 formed between the metal alloycoating layer 142 and metal strip 12 as shown in FIG. 12. The heatcreated intermetallic layer includes elements of the corrosion resistantmetal alloy molecularly intertwined with elements on the surface ofmetal strip 12. This molecular intertwining occurs when the temperatureof the surface of the metal strip approaches the temperature of themolten corrosion resistant metal alloy. The migration of the corrosionresistant metal atoms into the surface layer of strip 12 results in theformation of heat created intermetallic layer 140. A carbon steel stripcoated with a tin or tin and zinc metal alloy would form anintermetallic layer that includes at least iron, zinc, and tin. Astainless steel strip coated with a tin metal alloy would form anintermetallic layer that includes at least iron, chromium, and tin. Acopper or copper alloy strip coated with a tin and zinc metal alloywould form an intermetallic layer that includes at least copper, zinc,and tin. Intermetallic layer 140 can include a number of elements suchas, but is not limited to, antimony, aluminum, arsenic, bismuth,cadmium, chromium, copper, hydrogen, iron, lead, magnesium, manganese,nickel, nitrogen, oxygen, silicon, silver, sulfur, tellurium, tin,titanium, zinc and/or small amounts of other elements or compoundsdepending on the composition of the metal strip, the corrosion resistantalloy, and the intermediate barrier metal layer (if used). Heat createdintermetallic layer 140 can be thought of as a transition layer betweenmetal strip 12 and corrosion resistant alloy coating 142. Heat createdintermetallic layer 140 is believed to be at least partially responsiblefor the strong bond formed between corrosion resistant metal alloy layer142 and metal strip 12. The heat created intermetallic layer alsofunctions as a corrosion-resistant layer. Typically, the thickness ofthe heat created intermetallic layer is at least about 0.1 micron, andtypically about 1-50 microns; however, thicker heat createdintermetallic layers can be formed. The time needed to form the heatcreated intermetallic layer is typically less than about three minutesand generally less than about one minute; however, longer times can beused.

[0163] As shown in FIGS. 1B and 6, metal strip 12 passes between atleast one set of coating rollers 82 upon exiting the molten metal alloyin melting pot 70. As best shown in FIG. 6, the coating rollers arepartially immersed in protective material 78. As can be appreciated, thecoating rollers can be completely immersed in the protective material orpositioned above the protective material. Coating rollers 82 are spacedapart a sufficient distance so that metal strip 12 can pass between thecoating rollers. The coating rollers 82 are designed to maintain adesired coating thickness of the metal alloy on metal strip 12, removeexcess metal alloy 76 from metal strip 12, and/or coat any non-coatedregions on the surface of the metal strip. The coating thickness of themetal alloy is selected to ensure that essentially no uncoated regionsexist on the surface of the metal strip. Typically, the thickness of themetal alloy on the surface of metal strip 12 is at least about 1 micron,and generally about 7 to 2550 microns. The coating thickness istypically selected to ensure the coated metal alloy has essentially nopin holes, and/or does not shear when formed into various products. Thethickness of the metal alloy is selected depending on the environment inwhich the coated metal strip is to be used. A metal alloy coatingthickness of about 25-51 microns forms a coating that prevents, providesgreater elongation characteristics of the coated, and/or significantlyreduces the corrosion of the metal strip in virtually all types ofenvironments. Metal alloy coating thicknesses greater than about 51microns are typically used in harsh environments to provide addedcorrosion protection.

[0164] Referring again to FIGS. 1B and 6, a metal spray process is shownwherein metal coating jets or spray jets 84 inject molten metal alloy 76on the surface of coating rollers 82. As can be appreciated, metalcoating jets 84 can in addition to or in the alternative direct moltenmetal alloy onto the surface of metal strip 12. The molten metal alloythat is spray jetted onto coating roller 82 is then pressed againstmetal strip 12 by coating rollers 82 as the metal strip 12 moves betweenthe coating rollers thereby filling in any uncoated surface areas onmetal strip 12 which were not coated as the metal strip passed throughthe molten alloy in melting pot 70. As can be appreciated, the metalspray process and/or the coating rollers can be used independently ofthe melting pot and/or be the sole coating process used to coat themetal alloy onto the metal strip.

[0165] Referring now to FIG. 7, an air-knife 100 directs a high velocitygas toward metal alloy coating 76 on metal strip 12 as the metal stripexits melting pot 70. The air knife includes at least one blast nozzle104 that direct a high velocity gas onto the surface of the metal alloyon the metal strip. Typically, air knife includes at least two blastnozzles 104 which are mutually opposed from each other and are disposedover melting pot 70. The blast nozzles direct high velocity gas 105toward metal strip 12 and toward the surface of melting pot 70 as themetal strip moves by or between the blast nozzles. Generally, the blastnozzles are adjustable so as to direct the high velocity gas at variousangles on to the surface of the metal strip. The high velocity gasremoves surplus molten metal alloy coating 102 from the metal strip,smears the molten alloy on metal strip 12 to cover any uncoated regions,reduces the thickness of the metal alloy coating on the metal strip,reduces lumps or ribs in the metal alloy coating, and/or cools and/orhardens the metal alloy coating. The high velocity gas is typically aninert gas so as not to oxidize the molten metal alloy. Use of an inertgas also reduces dross formation on the metal alloy coating and/or actsas a protective barrier to the atmosphere which causes viscous oxides toform on the surface of the molten metal alloy in melting pot 70. Wheninert gas is used, the use of a protective material on the surface ofthe melting pot can be eliminated. Generally, the inert gas is, but isnot limited to, nitrogen or an inert gas that is heavier than air (i.e.has a higher density than air). The blast nozzles are typically enclosedin a box shaped sleeve which accumulates at least a portion of the gasafter the gas is directed toward the metal strip. The accumulated gascan then be recirculated back through the blast nozzles. When anair-knife is used to control the thickness and/or quality of the metalalloy coating, the air-knife is generally used as a substitute for orused in conjunction with coating rollers 82.

[0166] Referring now to FIG. 3, an alternative process for coating metalstrip 12 with a corrosion resistant metal alloy is illustrated. Metalstrip is shown to be coated with a corrosion resistant metal alloy by acontinuous electroplating process. This coating process is a non-hot-dipprocess in that a heat created intermetallic layer is not formed betweenthe metal strip and metal alloy coating. Metal strip 12 is directed intoelectrolytic tank 44 and submerged in electrolyte 46. Metal strip 12 canbe directed into electrolytic tank 44 immediately after being unrolledfrom metal roll 10; after being pretreated by one or more pretreatmentprocesses; and/or after being coated with metal alloy by immersion,spray metal coating, and/or roller coating. As metal strip 12 passesthrough electrolytic tank 44, an electrical current is directed intoelectrolyte 46 by electrodes 48. The current through electrodes 48 issupplied by power source 49. The plating of the metal alloy onto thesurface of the metal strip is typically effectuated by conventionalelectroplating processes. The metal alloy can be plated onto the surfaceof metal strip 12 by one or more plating operations. After the metalstrip is plated, the metal strip is moved out of electrolytic tank 44.The thickness of the plated corrosion resistant alloy is generally atleast about 1 micron, and typically less than about 200 microns. Coatingthickness of 2-77 microns, and 10-77 microns are typical coatingthicknesses. After the metal strip exits electrolytic tank 44, thecoated metal strip can be further treated by rinsing, pretreating,heating, coating with a metal alloy by a hot-dip process, and/or posttreatment.

[0167] When a heat created intermetallic layer is to be formed betweenthe metal strip and the plated metal alloy coating, the plated metalalloy coating is heated. FIG. 4 illustrates one heating process used toform a heat created intermetallic layer between the metal strip and theplated metal alloy coating. Coated metal strip is continuously movedbetween two heaters 58. Heaters 58 cause the plated corrosion resistantmetal alloy to soften and/or become molten. This process of heating theplated metal alloy is referred to as flow heating and constitutesanother type of hot-dip process. During the flow heating process, a heatcreated intermetallic layer is formed between the metal strip and metalalloy coating. The plated metal alloy is subjected to heat for asufficient time period to form a heat created intermetallic layer havinga desired thickness. As can be appreciated, the heating process canoccur is a single or a multiple stage process. Furthermore, the heatingprocess can be designed to heat a part of or the complete coated regionon the metal strip. After the metal strip is flow heated, the metalalloy coating can be further modified by a process such as, but notlimited to, controlling the coating thicknesses by an air-knife processand/or a coating roller process, and/or coating additional layers ofmetal alloy by additional coating process such as, but not limited to, aplating process, a metal spray process, a coating roller process, and/oran immersion process.

[0168] After metal strip 12 is coated with a corrosion resistant alloy,the coated metal strip is cooled and/or rinsed. A coated metal stripthat is plated as it moves through an electrolyte solution is typicallyrinsed off to remove electrolyte solution remaining on the surface ofthe coated metal strip. A coated metal strip that is coated by a hot-dipprocess is typically cooled to reduce the temperature and/or harden themetal alloy coating. Referring to FIGS. 1B, 8 and 10, the coated metalstrip is cooled by applying a cooling fluid 93 on the coated metal stripby at least one spray jet 92. Typically, the cooling fluid is, but notlimited to, water maintained at about ambient temperature. The velocityof the cooling fluid can be varied to obtain the desired cooling rateand/or rinsing effect of the corrosion resistant metal alloy. Asillustrated in FIGS. 1B and 10, metal strip 12 is guided by camel-backguides 90 during the cooling process. Camel-back guide 90 is designedsuch that it has two receding edges 91 formed by conical surfaces whichcontact only the edges of metal strip 12 so as to minimize the removalof the metal alloy coating from metal strip 12. Alternatively or inaddition to the spray cooling process, the coated metal strip can becooled in a cooling tank 94 as illustrated in FIG. 5. The coated metalstrip is partially or fully immersed in the cooling fluid 96 to cooland/or rinse the coated metal strip. Typically, the cooling fluid is,but not limited to, water maintained at about ambient temperature. Thecooling fluid is also typically agitated to increase the rate of coolingof the metal alloy coating, and/or maintain a relatively uniform coolingfluid temperature. The temperature of the cooling water is typicallymaintained at proper cooling temperatures by recycling the water throughheat exchangers and/or replenishing the cooling fluid. The cooling watermay not be deoxygenated prior to cooling the coated metal strip coatingso as to slightly discolor the metal alloy coating and/or reduce thereflectiveness of the metal alloy coating. Immersion of the coated metalstrip in cooling fluid 96 generally results in a faster cooling ratethan cooling by spray jets 92. Rapid cooling of the corrosion resistantmetal alloy generally produces a metal alloy coating having fine grainsize with increased grain density. In addition, cooling of the metalalloy coating in water results in some oxidation of the metal alloycoating surface which forms a less-reflective surface. The coolingperiod for cooling coated metal strip 12 by cooling jets 92 or byimmersion in cooling tank 94 is generally less than about two minutes,and typically about 10-30 seconds.

[0169] After the coated metal strip is cooled, the coated metal stripmay be rolled into a metal roll, partially or totally formed intovarious shapes (i.e. roofing materials, building materials, householdparts, automotive parts, etc.), oxidized to partially or fully exposethe heat created intermetallic layer, and/or passify the heat createdintermetallic layer prior to the coated metal strip being rolled, cutinto sheets and/or formed.

[0170] As illustrated in FIG. 15, the metal strip is unrolled andimmediately directed into a molten bath of metal alloy without any priorpretreatment processes. Upon exiting the molten metal bath, the metalstrip passes between coating rollers and is then subjected to anair-knife process to control the coating thickness and uncoated regionson the metal strip surface. The air-knife also cools and hardens themetal alloy coating so that the coated metal strip can be immediatelyrolled into a metal roll 150.

[0171] As illustrated in FIG. 2, the coated metal strip can be furtherprocessed prior to being rolled into a metal roll 150 or cut in tosheets 130. This further processing includes, but is not limited to,leveling, shearing, oxidizing the coated corrosion resistant alloy,passifying the metal alloy and/or heat created intermetallic layer,applying weathering agents, applying paints, sealants etc. As shown inFIG. 2, the coated metal strip is subjected to a leveler 100. Leveler100 includes several rollers 102 which produce a uniform and smoothcorrosion resistant alloy coating 142 on metal strip 12. After metalstrip 12 exits leveler 100, metal strip 12 is illustrated as being cutinto sheets 130 by shear 111. The coated metal sheets or strip can befurther processed by applying a paint, sealant or weathering agent onthe surface of the coated metal sheets or strip. The paint, sealant orweathering agent 112 can be applied to a portion or the full surface ofthe coated metal alloy. The paint, sealant or weathering agent can beapplied by coaters 114 and/or by sprayers 116. A reservoir 110 holds thepaint, sealant or weathering agent for coaters 114 and/or sprayers 116.After the paint, sealant or weathering agent is applied, it is dried byheat lamp 120 and/or by a dryer 122.

[0172] When a weathering agent is applied to the coated metal strip, theweathering agent is used to accelerate the patina formation on the metalalloy coating. This process is generally used to discolor the metalalloy and/or reduce the reflectiveness of the metal alloy. The naturalweathering of the metal alloy can take, in some instances, over tenyears to weather to the desired degree. The weathering agent isformulated to reduce the time period of weathering. In one formulation,the weathering agent is typically a petroleum based product. Generally,the petroleum based weathering agent is an asphalt based paintcontaining a suspension of free carbon and a thinner. When thisformulation is used, a thin film or coating of weathering agent isapplied to the surface of the metal alloy and the ultraviolet light fromthe atmosphere facilitates in accelerating the weathering of the metalalloy. Generally, the thin layer of weathering agent is asemi-transparent or translucent coating and at least partially allowsthe metal alloy to be exposed to oxygen, moisture and to the sun'sradiation. The weathering agent can include, but is not limited to,asphalt, titanium dioxide, inert silicates and low clay, carbon black(lampblack) or other free carbon and an anti-settling agent. The asphaltmakeup of the weathering agent is typically about 60% to 80% by weightof the weathering agent, preferably about 64% to 78% by weight of theweathering agent, and more preferably about 68% by weight of theweathering agent. The amount of titanium oxide in the weathering agentis about 1% to 25% by weight of the weathering agent, and preferablyabout 19% by weight of the weathering agent. Preferably, over 50% of thetitanium oxide is anatase grade. When carbon black is added to theweathering agent, the carbon black is present in an amount of up toabout 2% by weight of the weathering agent, preferably about 0.5 to 1%by weight of the weathering agent, and more preferably about 0.7% byweight of the weathering agent. The inert silicates and/or low clay,such as, but not limited to calcium borosilicate, when added to theweathering agent, is present in an amount of about 8-11% by weight ofthe weathering agent. The antisettling agent, when added to theweathering agent, is present in an amount of about 0.4-0.7% by weight ofthe weathering agent, and preferably about 0.5% by weight of theweathering agent. One specific formulation of the weathering agentincludes about 60-80 weight percent asphalt, about 1-25 weight percenttitanium oxide, about 8-11 weight percent inert silicates and clay,about 0.5-2 weight percent carbon black, about 0.4-0.7 weight percentanti-settling agent, and solvent. Another specific formulation of theweathering agent includes 65-75 weight percent gilsonite, 15-20 weightpercent titanium oxide, 8-11 weight percent calcium borosilicate, 0.5-1weight percent carbon black, 0.4-0.6 weight percent anti-settling agent,and solvent. Still another specific formulation of the weathering agentincludes 64-78 weight percent gilsonite, 11.68-20.5 weight percenttitanium oxide, 8.4-10.3 weight percent inert silicates and clay,0.63-0.77 weight percent carbon black, 0.4-0.52 weight percentanti-settling agent, and solvent. Yet another specific formulation ofthe weathering agent includes 70.86 weight percent gilsonite, 18.65weight percent titanium oxide, 9.32 weight percent calcium borosilicate,0.7 weight percent carbon black, 0.47 weight percent anti-settlingagent, and solvent. A solvent such as, but not limited to, naphthaleneand/or paint thinners, is used to thin the weathering agent so that athin, translucent or semi-translucent film can be formed on the surfaceof the metal alloy. The thickness of the weather agent layer isgenerally less than about 123 mils, more typically about 6-123 microns,even more typically up to about 50 microns, yet even more typically upto about 25 microns, and still more typically about 12-25 microns. Thecolor of the weathering agent is a dull, lackluster color which has lowreflective properties. As a result, the weathering agent accelerates thepatina formation on the metal alloy coating and reduces the reflectiveproperties of the newly applied or formed metal alloy. Another type ofweathering agent which can be used is disclosed in U.S. Pat. No.5,296,300, which is incorporated herein.

[0173] Metal strip 12 can be oxidized to partially or fully expose theheat created intermetallic layer prior to or subsequent to the coatedmetal strip being rolled into a metal roll, cut into sheets of strip,and/or formed into various shapes. To expose the heat createdintermetallic layer, the coated metal alloy can be ground off and/orchemically removed. Typically the metal alloy coating is chemicallyremoved by an oxidizing solution. As shown in FIG. 13, coated metalstrip is immersed in oxidizing solution 133 in oxidizing tank 132. Theoxidizing solution is formulated to at least partially removes the metalalloy coating from metal strip 12 thereby at least partially exposingheat created intermetallic layer 140. The intermetallic layer has beenfound to be an excellent corrosion resistant layer. The oxidizing tank132 typically includes an agitator to prevent or reduce stagnationand/or vast concentration differences of the oxidizing solution in thetank, prevent or reduce gas bubbles from forming on the surface of metalstrip 12, and/or maintain a substantially uniform temperature in theoxidizing solution. The oxidizing solution typically includes an acidsuch as, but not limited to, nitric acid. When nitric acid is includedin the oxidation solution, the nitric acid concentration is generallyabout 5%-60% by volume and typically about 10-25% by volume, moretypically about 25% by volume, and even more typically about 20% byvolume. Copper sulfate is generally added to the acid in the oxidizingsolution to improve the oxidation of the metal alloy coating. Coppersulfate, when present, is generally added in a concentration of lessthan about 10% by volume, typically about 0.5-2% by volume, and moretypically about 1% by volume. The temperature of the oxidizing solutionis maintained at a temperature that provides sufficient activity of theoxidizing solution. Generally, the temperature is maintained betweenabout 20-80° C., typically about 30-80° C., more typically about 40-60°C., and even more typically about 50° C. By increasing the concentrationand/or temperature of the oxidation solution, the time needed to atleast partially remove the metal alloy coating 76 is shortened. Theamount of time to remove the desired amount of the metal alloy coatingis generally less than about ten minutes, typically less than about twominutes, more typically about 0.08-1.5 minutes; however, longer timescan be used, and even more typically about 0.33 minutes. The exposedheat created intermetallic layer is typically has a dark grey,non-reflective surface. As can be appreciated, the oxidation solutioncan be applied to the coated metal strip after or just prior to themetal strip being formed and/or installed. In this instance, theoxidizing solution can be swabbed or sprayed onto the surface of thecoated metal strip.

[0174] Once the desired amount of metal alloy coating is removed, theexposed heat created intermetallic layer is typically passivated toenhance the corrosion-resistance of the intermetallic layer. Theintermetallic layer is generally passivated by a passivating solution.One type of passivating solution includes a nitrogen containing solutionand/or a chromium solution such as, but not limited to, nitric acidand/or chromate acid. The passivation solution can be the same as ordifferent from the oxidizing solution. When chromate acid is included inthe passivation solution, the concentration of chromate acid isgenerally about 0.5-5 g/liter. Phosphate can be added to the passivationsolution to enhance the passivation of the metal alloy. When thepassivation solution and the oxidizing solution are the same, theremoval of metal alloy coating and passivation of the heat createdintermetallic layer can both be accomplished in a single tank. In asingle tank arrangement, the passivation solution and the oxidizingsolution are formulated such that when the heat created intermetalliclayer is exposed and then passified, the passivated layer is not removedor very slowly removed by the passivation solution and the oxidizingsolution, thus making the oxidation and passivation processautocatalytic or semi-autocatalytic. As illustrated in FIG. 13, metalstrip 13 is directed into a passivation tank 135 after being oxidized inoxidation tank 132. The passivation tank 132 typically includes anagitator to prevent or reduce stagnation and/or vast concentrationdifferences of the passivation solution in the tank, prevent or reducegas bubbles from forming on the surface of metal strip 12, and/ormaintain a substantially uniform temperature for the passivationsolution. The temperature of the passivation solution is maintained at atemperature that provides sufficient activity of the passivationsolution. Generally, the temperature of the passivation solution ismaintained between about 15-80° C., typically about 40-60° C. Byincreasing the concentration and/or temperature of the passivationsolution, the time needed to at least partially passivate the exposedheat created intermetallic layer is shortened. The amount of time topassivate the heat created intermetallic layer is generally less thanabout ten minutes, and typically about 0.02-1.5 minutes; however, longertimes can be used.

[0175] Referring now to FIG. 14, passivation layer 146 is a very thinlayer. Generally, the thickness of the passivation layer is less thanabout 13 microns, typically less than about 3 microns, and moretypically up to about 1.5 microns. The passivation layer facilitates ininhibiting or preventing oxidation (i.e. white rust) of the outer metallayer. The passivation layer 146 significantly enhances thecorrosion-resistance of the intermetallic layer 142. Although it is notentirely known how passivation layer 148 exhibits increased corrosionresistance, it is believed that a unique covalently bonded system isformed when the intermetallic layer is passified. When the intermetalliclayer 142 is passified with passivation solution 162, a chemicalreaction is believed to occur to modify the atomic structure ofpassivation layer 146. Other elements such as, but not limited to,nitrogen, hydrogen, oxygen may also be present in passivation layer 146to enhance the stability of passivation layer 146. The specialformulation of the intermetallic layer 142 in combination with thepassivation layer 146 provides for superior corrosion resistance formetal strip 12. Passivation layer 146 is also malleable and will notcrack when formed into various shapes. Passivation layer 146 isgenerally a grey, earth tone color non-reflective surface. Passivationlayer 146 displays increased corrosion resistance, abrasion resistance,and increased hardness as compared to the heat created intermetalliclayer. Heat created intermetallic layer 142 and passivation layer 146are also resistant to scratching thereby improving the visual quality ofmetal strip 12 and enhancing the damage resistance of metal strip 12.The relative nonexistence of lead in intermetallic layer 142 andpassivated layer, especially when low lead metal alloys are used, makesthe passivated metal strip a superior substitute to terne coatedmaterials. Not only is the corrosion resistance of the intermetalliclayer and passivated layer greater than terne coatings, theintermetallic layer and the passivated layer contain little, if any,lead thereby alleviating any concerns associated with the use of leadmaterials.

[0176] After metal strip 12 is oxidized or passified, metal strip 12 istypically rinsed to remove any oxidation solution or passivationsolution remaining of the metal strip. The rinse process can beperformed by liquid spray jets and/or immersion of the metal strip in atank that contains a rinse solution. Typically, the rinse liquid isabout ambient temperature. The rinse tank, when used, typically includesan agitator to assist in the removal of the oxidizing solution and/orpassivation solution from metal strip 12. Once the rinse process iscomplete, the metal strip is rolled into strip roll 150, cut into sheets130, preformed to various articles, and or painted or sealed.

[0177] Referring now to FIGS. 16-18, a fuel tank is formed from coatedmetal strip 12. Fuel tank 160 is made up of two shell members 162 and164. The shell members are each shaped in a die by placing the coatedmetal strip or a section thereof on a die and drawing the coated metalstrip over the die. The shells are typically formed in a cylindricalshape and each have a peripheral edge 166; however, other shapes can beformed. The two shells are joined together at the respective peripheraledges to form an inner fuel receiving chamber 168 wherein the fuel isstored within the tank. Fuel tank 160 also contains a spout 170 whichcommunicates with interior chamber 168 of the fuel tank so that the fuelcan be inserted into the inner chamber. Typically, the spout is insertedat the top portion of shell 162 for easy insertion of the fuel into thetank; however, the spout can be located in other areas. Fuel tank 160also contains a drain hole 172 which communicates with the interior ofthe fuel tank chamber with the fuel system of the motor vehicle.Typically, drain hole 172 is located at the top of the fuel tank onshell 162; however, the drain hole can be located in other areas. A fuelpump can be located in the inner chamber of the fuel tank to pump thefuel through the vehicle's fuel system.

[0178] As illustrated in FIG. 18, shell members 162 and 164 are joinedtogether by abutting and connecting together peripheral edges 166 of therespective shell members. Typically, the peripheral edges are connectedtogether a weld or solder 180. Spout 170 and drain hole 172 are alsoconnected to the shell member typically by a weld or solder. Generally,the weld or solder is essentially lead-free so as not to add any lead tothe fuel tank. Each shell member includes a corrosion resistant metalalloy coating 186 and an inner corrosion resistant metal alloy coating188, both of which having substantially the same thickness. When thecoated metal strip is drawn over the die, the corrosion resistant metalalloy coating 186, 188 becomes elongated about the peripheral edgecorner 190. When corrosion resistant metal alloy coating is elongated,the corrosion resistant metal alloy coating reduces in thickness. If thecorrosion resistant alloy coating is too thin, the alloy coating willtear or shear and expose the unprotected surface of metal strip 12.Typically, the thickness of the corrosion resistant metal alloy coatingis at least about 25 microns so that as the metal alloy coating can beelongated and shaped by the die without shearing and exposing thesurface of the metal strip.

[0179] Referring now to FIGS. 19-20, building materials such as roofingpanels are formed from the coated metal strip. Roofing panels P arejoined together by an elongated standing seam S. Roofing panels P areformed on site or preformed in the shape of elongated pans as shown inFIG. 19. Pans 200 and 202 have substantially similar features. Both panshave a right edge portion 204 and a left edge portion 206. As shown inFIG. 20, pans 202 and 204 are adjacently positioned together to definethe elongated direction D lying along base line X. A cleat 210 is usedto form seal S. Nails 212 maintain the pans on roof 220 while seam S isformed. In standing seam applications, the edges of the roofingmaterials are folded together and then soldered to form a water tightseal. The metal alloy coating inherently includes excellent solderingcharacteristics. The metal alloy coating can be also welded or soldered.Typical solders contain about 50% tin and about 50% lead. The metalalloy has the added advantage of being solderable with low or no-leadsolders. The roofing materials can be used in mechanically joinedroofing systems due to the malleability of the metal alloy. Mechanicallyjoined systems form water tight seals by folding adjacent roof materialedges together and subsequently applying a compressive force to the seamin excess of about 1,000 psi. Under these high pressures, the metalalloy plastically deforms within the seam and produces a water tightseal. This type of roofing system is disclosed in U.S. Pat. Nos.4,934,120; 4,982,543; 4,987,716; 4,934,120; 5,001,881; 5,022,203;5,259,166; and 5,301,474, which are incorporated herein by reference.

[0180] Referring now to FIG. 21, a corrosion resistant metal alloy isformed into a metal alloy strip 230 by a roll forming process. As can beappreciated, the metal alloy can alternatively be formed into a wire, atube, or molded or cast into other-shapes. Ingets of tin or tin and zincare placed into the melting pot 240 wherein the tin or the tin and zincingots are melted. The molten metal alloy is maintained above itsmelting point in the melting pot. Other metals such as, but not limitedto, iron, nickel, aluminum, titanium, copper, manganese, bismuth,antimony can be added into the melting pot to alter the composition ofthe metal alloy. The inclusion of these other metals typically altersthe melting point of the metal alloy. In order to accommodate for thehigh melting temperature of the metal alloy, the melting pot is made ofmaterials to withstand these higher temperatures. Once the metal alloyis properly mixed and melted in melting pot 240, the molten alloy isallowed to flow out of the bottom of the melting pot through pot opening242. The molten metal alloy 230 is then directed through one or moresets of rollers 260 until the desired thickness of the metal alloy sheetor strip is obtained. The process of roll forming metal strip is wellknown in the art, thus further details as to the forming of the metalalloy strip 230 will not be discussed.

[0181] The thickness of the formed metal alloy strip 230 is typicallyless than about 5080 microns. Once metal alloy strip 230 has passedthrough rollers 260, metal alloy strip 230 may be further processed,such as by a pretreatment processes, a coating process, and/or a postcoating process as discussed above.

[0182] As shown in FIG. 21, metal alloy strip 230 is directed into apassivation tank 270. Passivation tank 270 includes a passivationsolution 272. The passivation solution is typically the same passivationsolution as described above. As the metal alloy strip is directed intopassivation tank 270, guide rollers 280 guide the metal alloy strip. Thepassivation solution reacts with the surface of the metal alloy strip toform a passivation layer which is highly corrosion resistant. Thepassivation solution also causes the surface of the metal strip tochange colors. The passivation tank generally includes an agitator toprevent or inhibit stagnation and/or vast concentration differences ofthe passivation solution in the passivation tank.

[0183] After metal alloy strip 230 passes through the passivation tank,the metal alloy strip typically proceeds to a rinsing process, notshown, to remove passivation solution remaining on the metal alloystrip. Generally, the passivation solution is removed by passing themetal alloy strip through a rinse tank and/or by spraying the metalalloy strip with a rinse fluid.

[0184] As shown in FIG. 21, after metal alloy strip is passivated, thestrip is rolled into a roll 290 of metal alloy strip.

[0185] As can be appreciated, the molten metal alloy can be formed intoa wire or tube. Such wire or tube can be used for pipes, wire, cable,solder or welding wire. When the metal alloy is formed into a solder orwelding wire, the metal alloy is generally not passivated. The solder orwelding wire has been found to form a strong bond with the metalmaterials and has excellent wetting properties to create a high qualitybond. The solder also has good conductive properties so that it can beused to form electrical connections. The types of base metals which canbe soldered by the metal alloy include, but are not limited to, carbonsteel, stainless steel, copper, copper alloys, aluminum, aluminumalloys, nickel alloys, tin, titanium, titanium alloys. Materials coatedwith tin, tin metal alloys, zinc, zinc alloys, tin and zinc metalalloys, lead, lead and tin alloys, and various other metals can also besoldered or welded by the metal alloy. The metal alloy strip can also beformed into roofing materials and/or gasoline tanks, as described above,or a variety of components.

[0186] The corrosion resistant metal alloy is a tin metal alloy or a tinand zinc metal alloy. Both of these metal alloys exhibit excellentbonding and corrosion resistant properties when applied to a metal stripby a hot dip process or by a plating process.

[0187] The tin metal alloy is formulated to include at least a majorityof tin. Generally, the tin metal alloy includes at least about 75 weightpercent tin, typically at least about 90 weight percent tin, moretypically at least about 95 weight percent tin, even more typically atleast about 98 weight percent tin, and still even more typically atleast about 99 weight percent tin. The high percentage of tin in the tinmetal alloy is substantially different from standard terne alloyformulations which contain about 80% lead and 20% tin. The highconcentration of tin in the tin metal alloy increases the uniformity andstrength of the bond between the tin metal alloy and many types of metalstrip 12 as compared with standard terne alloy coatings. The superiorbonding characteristics of the tin metal alloy makes the tin metal alloycoating ideal for use with many different types of metal stripcompositions, and can be formed in a variety of simple and complexshapes. Industrial grade tin typically is used as the tin source for thetin metal alloy; however, other sources of the tin can be used.Industrial grade tin typically contains trace amounts of impurities suchas, but not limited to, cobalt, nickel, silver and sulphur. It has beenfound that these elements in controlled amounts do not adversely affectthe corrosive resistive properties of the tin metal alloy. Indeed,elements such as, but not limited to, nickel can enhance some propertiesof the tin alloy.

[0188] The tin and zinc metal alloy is a special combination of tin andzinc. The tin and zinc metal alloy is formulated to include at leastabout 10 weight percent zinc and at least about 15 weight percent tin.It has been found that the addition of zinc in the amount of at leastabout 10 weight percent of the tin and zinc metal alloy produces a metalalloy having enhanced corrosion-resistance in various types ofenvironments. The tin content of the tin and zinc metal alloy isgenerally about 15-90 weight percent. The zinc content of the alloy isgenerally about 10-85 weight percent. The tin plus zinc content of thetin and zinc metal alloy typically constitutes at least a majority ofthe tin and zinc metal alloy. Typically, tin plus zinc content of thetin and zinc metal alloy constitutes at least about 75 weight percenttin and zinc, more typically at least about 80 weight percent tin andzinc, even more typically at least about 90 weight percent tin and zinc,still even more typically at least about 95 weight percent tin and zinc,yet still even more typically at least about 98 weight percent tin andzinc, and yet still even more typically at least about 99 weight percenttin and zinc. The tin and zinc formulation oxidizes to form a coloredcoating which closely resembles the popular grey, earth-tone color ofweathered terne. The use of large weight percentages of zinc in the tinand zinc metal alloy does not cause the coating to become too rigid ortoo brittle. The tin and zinc metal alloy is formable thus can be bentinto simple or complex shapes without cracking or breaking. Themalleability of tin and zinc metal alloy is believed to be at partiallythe result of the unique tin and zinc distributions within the tin andzinc metal alloy. The tin and zinc form a two phase matrix wherein zincglobules are surrounded by tin. Zinc facilitates in stabilizing the tinin the tin and zinc metal alloy so as to inhibit or prevent tincrystallization in the tin and zinc alloy. When determining thecomposition of the tin and zinc metal alloy, the environment the coatingis to be used in should be considered. In some situations, a higher tinconcentration may be beneficial to limit the amount of zinc richglobules in the tin and zinc metal alloy. In other environments, thereverse may be true. The tin metal alloy or the tin and zinc metal alloytypically contains one or more additives without adversely affecting thetin metal alloy or the tin and zinc metal alloy. The additives areincluded and/or added to tin metal alloy or the tin and zinc metal alloyto modify the mechanical properties of the metal alloy, thecorrosion-resistance of the metal alloy, the color of the corrosionresistant metal alloy, the stability of the metal alloy, and/or thecoating properties of the metal alloy. The additive(s) generallyconstitute less than about 25 weight percent of the metal alloy.Typically, the additive(s) constitute less than about 10 weight percentof the metal alloy. The content of the additives is controlled so thatthe additives properly mix with the metal alloy. The proper mixing ofthe additives in the metal alloy is of greater importance for a tin andzinc metal alloy wherein the tin and zinc form a special two phasematrix. Typically, the additives are added to a tin and zinc alloy in amanner that maintains the two phase matrix of the tin and zinc so as notto form a tin and zinc alloy having more than two phases or whichdisrupts the tin and zinc matrix.

[0189] The tin metal alloy typically includes at least an effectiveamount of one or more stabilizing additives to inhibit or prevent thetin from crystallizing. Tin and zinc metal alloys can also includestabilizing additives; however, such additives can be eliminated sincethe zinc in the tin and zinc alloy generally facilitates in stabilizingthe tin to inhibit or prevent the tin from crystallizing. Tin can beginto crystallize when the temperature drops below about 13° C.Crystallization of the tin in the alloy can weaken the bond between themetal strip and the metal alloy and can result in flaking of the metalalloy from the metal strip. The addition of small amounts of stabilizingmetals such as, but not limited to, antimony, bismuth, cadmium, copper,zinc and mixtures thereof prevent and/or inhibit the crystallization ofthe tin in the metal alloy. Only small amounts of antimony, bismuth,cadmium and/or copper are needed to stabilize the tin in the metal alloyand inhibit and/or prevent the tin from crystallizing. Amounts of atleast about 0.001-0.01 weight percent of the metal alloy are generallysufficient to inhibit or prevent tin crystallization. Typically, the oneor more stabilizers are included in an amount of at least about0.001-0.005 weight percent of the metal alloy to inhibit crystallizationof the tin.

[0190] The tin metal alloy or tin and zinc metal alloy can include otheradditives to alter and/or enhance one or more properties of the metalalloy. The metal alloy can include at least an effective amount ofcorrosion-resistant agent to enhance the corrosion-resistant propertiesof the metal alloy. The corrosion-resistant agent includes, but is notlimited to, antimony, bismuth, cadmium, chromium, copper, lead,manganese, magnesium, nickel, titanium and/or zinc. The metal alloy caninclude at least an effective amount of coloring agent to alter thecolor of the metal alloy. The coloring agent includes, but is notlimited to, cadmium, copper, iron, lead, silver and/or titanium. Themetal alloy can include at least an effective amount of reflective agentto positively alter the reflectiveness of said metal alloy. Thereflective agent includes, but is not limited to, aluminum, cadmium,chromium, copper, silver and/or titanium. A metal alloy which includes asufficient amount of coloring agents and/or reflective agent may not berequired to be weathered prior to use in certain applications. The metalalloy can include at least an effective amount of grain agent topositively alter the grain density of the metal alloy. The grain agentincludes, but is not limited to, cadmium, manganese and/or titanium. Themetal alloy can include at least an effective amount of mechanical agentto positively alter the mechanical properties of the metal alloy. Themechanical properties of the metal alloy include, but are not limitedto, the strength of the metal alloy, the hardness of the metal alloy,the pliability of the metal alloy, the elongation of the metal alloy,the tensile strength of the metal alloy, the elasticity of the metalalloy, the rigidity of the metal alloy, the conductivity of the metalalloy, the heat transfer properties of the metal alloy, etc. Themechanical agent includes, but is not limited to, aluminum, antimony,arsenic, bismuth, cadmium, chromium, copper, iron, lead, magnesium,manganese, nickel, silver, titanium and/or zinc. The metal alloy caninclude at least an effective amount of deoxidizing agent to reduce theamount of oxidation of the metal alloy in a molten state. Thedeoxidizing agent includes, but is not limited to, aluminum, cadmium,magnesium, manganese and/or titanium. The metal alloy can include atleast an effective amount of bonding agent to enhance the bondingproperties of the metal alloy to the metal strip and/or intermediatebarrier metal layer. The bonding agent includes, but is not limited to,cadmium, lead, manganese, titanium and/or zinc.

[0191] Aluminum, if added to and/or included in the metal alloy, isgenerally present in amounts up to about 5 weight percent of the metalalloy; however, higher weight percentages can be used. In severalaspects of the present invention, the aluminum content of the metalalloy is a) up to about 2 weight percent of the metal alloy, b) up toabout 1 weight percent of the metal alloy, c) up to about 0.75 weightpercent of the metal alloy, d) up to about 0.5 weight percent of themetal alloy, f) up to about 0.4 weight percent of the metal alloy, g) upto about 0.3 weight percent of the metal alloy, h) up to about 0.25weight percent of the metal alloy, i) at least about 0.05 weight percentof the metal alloy, j) about 0.1-1 weight percent of the metal alloy, k)about 0.1-0.5 weight percent of the metal alloy, 1) about 0.1-0.3 weightpercent of the metal alloy, m) about 0.01-1 weight percent of the metalalloy, n) about 0.01-0.5 weight percent of the metal alloy, o) about0.01-0.3 weight percent of the metal alloy, p) about 0.01-0.1 weightpercent of the metal alloy, q) about 0.0005-0.75 weight percent of themetal alloy, r) about 0.001-0.5 weight percent of the metal alloy, s)about 0.001-0.4 weight percent of the metal alloy, t) about 0.002-0.4weight percent of the metal alloy, u) about 0.001-0.4 weight percent ofthe metal alloy, v) about 0.001-0.01 weight percent of the metal alloy,and w) about 0.0001-0.005 weight percent of the metal alloy, x) about0.001-0.005 weight percent of the metal alloy, and y) less than about0.001 weight percent of the metal alloy. When aluminum is added to themetal alloy, the aluminum is typically added in the form of an alloysuch as, but not limited to, Al—Cu—Mg alloy.

[0192] Antimony, if added to and/or included in the alloy, is generallypresent in amounts up to about 7.5 weight percent of the metal alloy;however, higher weight percentages can be used. In several aspects ofthe present invention, the antimony content of the metal alloy is a) upto about 5.5 weight percent of the metal alloy, b) up to about 2.5weight percent of the metal alloy, c) up to about 2 weight percent ofthe metal alloy, d) up to about 1 weight percent of the metal alloy, e)up to about 0.75 weight percent of the metal alloy, f) up to about 0.5weight percent of the metal alloy, g) about 0.001-1 weight percent ofthe metal alloy, h) about 0.005-0.8 weight percent of the metal alloy,i) about 0.01-0.8 weight percent of the metal alloy, j) about 0.01-0.5weight percent of the metal alloy, and k) about 0.05-0.5 weight percentof the metal alloy.

[0193] Bismuth, if added to and/or included in the metal alloy, isgenerally present in amounts up to about 1.7 weight percent of the metalalloy; however, higher weight percentages can be used. In severalaspects of the present invention, the bismuth content of the metal alloyis a) up to about 1 weight percent of the metal alloy b) up to about 0.5weight percent of the metal alloy, c) up to about 0.01 weight percent ofthe metal alloy, d) about 0.0001-0.5 weight percent of the metal alloy,e) about 0.05-0.5 weight percent of the metal alloy, f) about 0.0001-0.2weight percent of the metal alloy, g) about 0.002-0.1 weight percent ofthe metal alloy, and h) about 0.001-0.01 weight percent of the metalalloy.

[0194] Cadmium, if added and/or included in the metal alloy, is presentin amounts of up to about 0.5 weight percent of the metal alloy;however, higher weight percentages can be used. In several aspects ofthe present invention, the cadmium content of the metal alloy is a) upto about 0.1 weight percent of the metal alloy, and b) less than about0.05 weight percent of the metal alloy.

[0195] Chromium, if added and/or included in the metal alloy, is presentin amounts of at least about 0.0001 weight percent. In several aspectsof the present invention, the chromium content of the metal alloy is a)less than about 0.1 weight percent of the metal alloy, and b) up toabout 0.02 weight percent of the metal alloy.

[0196] Copper, if added to and/or included in the metal alloy, ispresent in amounts up to about 5 weight percent of the metal alloy;however, higher weight percentages can be used. In several aspects ofthe present invention, the copper content of the metal alloy is a) up toabout 2.7 weight percent of the metal alloy, b) up to about 2 weightpercent of the metal alloy, c) up to about 1.6 weight percent of themetal alloy, d) up to about 1.5 weight percent of the metal alloy, e) upto about 1 weight percent of the metal alloy, f) up to about 0.05 weightpercent of the metal alloy, g) at least about 0.001 weight percent ofthe metal alloy, h) at least about 0.1 weight percent of the metalalloy, i) about 0.001-2.7 weight percent of the metal alloy, j) about0.01-2.7 weight percent of the metal alloy, k) about 0.001-1.6 weightpercent of the metal alloy, 1) about 0.1-1.6 weight percent of the metalalloy, m) about 0.1-1.5 weight percent of the metal alloy, n) about0.001-1 weight percent of the metal alloy, o) about 0.001-0.5 weightpercent of the metal alloy, p) about 0.005-0.6 weight percent of themetal alloy, q) about 0.005-0.1 weight percent of the metal alloy, r)about 0.01-0.1 weight percent of the metal alloy, s) about 0.05-0.1weight percent of the metal alloy, t) about 0.005-2.7 weight percent ofthe metal alloy, u) about 0.005-1.6 weight percent of the metal alloy,and v) about 0.1-1.5 weight percent of the metal alloy. When copper isadded to the metal alloy, the copper is typically added in the form ofbrass and/or bronze.

[0197] Iron, if added to and/or included in the metal alloy, is added inamounts up to about 1 weight percent of the metal alloy; however, higherweight percentages can be used. In several aspects of the presentinvention, the iron content of the metal alloy is a) less than about 0.5weight percent of the metal alloy, b) less than about 0.1 weight percentof the metal alloy, c) up to about 0.02 weight percent of the metalalloy, d) less than about 0.01 weight percent of the metal alloy, e)less than about 0.005 weight percent of the metal alloy, and f) lessthan about 0.002 weight percent of the metal alloy.

[0198] Lead, if added to and/or included in the metal alloy, is presentin low levels, generally less than about 10 weight percent of the metalalloy; however, higher weight percentages can be used. In severalaspects of the present invention, the lead content of the metal alloy isa) less than about 2 weight percent of the metal alloy, b) less thanabout 1 weight percent of the alloy, c) less than about 0.5 weightpercent of the alloy, d) less than about 0.1 weight percent of the metalalloy, e) less than about 0.075 weight percent of the metal alloy, f)less than about 0.06 weight percent of the metal alloy, g) less thanabout 0.05 weight percent of the metal alloy, h) less than about 0.02weight percent of the metal alloy; i) less than about 0.01 weightpercent of the metal alloy, j) less than about 0.001 weight percent ofthe metal alloy, and k) about 0.001-0.1 weight percent.

[0199] Magnesium, if added to and/or included in the metal alloy, ispresent in amounts up to about 5 weight percent of the metal alloy;however, higher weight percentages can be used. In several aspects ofthe present invention, the magnesium content of the metal alloy is a) upto about 2 weight percent of the metal alloy, b) up to about 1 weightpercent of the metal alloy, c) up to about 0.4 weight percent of themetal alloy, d) up to about 0.1 weight percent of the metal alloy, e)about 0.1-0.4 weight percent of the metal alloy, f) about 0.01-0.4weight percent of the metal alloy, and g) about 0.001-0.1 weight percentof the metal alloy. When magnesium is added to the metal alloy, themagnesium is typically added in the form of pure magnesium.

[0200] Manganese, if added to and/or included in the metal alloy, ispresent in amounts up to about 0.1 weight percent of the metal alloy;however, higher weight percentages can be used. In several aspects ofthe present invention, the manganese content of the metal alloy is a) atleast about 0.0001 weight percent of the metal alloy, b) up to about0.01 weight percent of the metal alloy, c) about 0.0001-0.1 weightpercent of the metal alloy, d) about 0.001-0.1 weight percent of themetal alloy, and e) about 0.0001-0.01 weight percent of the metal alloy.

[0201] Nickel, if added to and/or included in the metal alloy, ispresent in amounts up to about 5 weight percent of the metal alloy;however, higher weight percentages can be used. In several aspects ofthe present invention, the nickel content of the metal alloy is a) up toabout 2 weight percent of the metal alloy, b) up to about 1 weightpercent of the metal alloy, c) up to about 0.9 weight percent of themetal alloy, d) up to about 0.7 weight percent of the metal alloy; e) upto about 0.3 weight percent of the metal alloy, f) up to about 0.1weight percent of the metal alloy, g) up to about 0.005 weight percentof the metal alloy, h) about 0.001-0.1 weight percent of the metalalloy, i) about 0.001-0.9 weight percent of the metal alloy, j) about0.001-0.3 weight percent of the metal alloy, k) about 0.001-0.05 weightpercent of the metal alloy, 1) about 0.001-0.005 weight percent of themetal alloy, and m) about 0.01-0.7 weight percent of the metal alloy.

[0202] Titanium, if added to and/or included in the metal alloy, ispresent in amounts up to about 1 weight percent of the metal alloy;however, higher weight percentages can be used. In several aspects ofthe present invention, the titanium content of the metal alloy is a) upto about 0.5 weight percent of the metal alloy, b) up to about 0.2weight percent of the metal alloy, c) up to about 0.18 weight percent ofthe metal alloy; d) up to about 0.15 weight percent of the metal alloy;e) up to about 0.1 weight percent of the metal alloy, f) up to about0.075 weight percent of the metal alloy, g) up to about 0.05 weightpercent of the metal alloy, h) at least about 0.0005 weight percent ofthe metal alloy, i) about 0.01-0.5 weight percent of the metal alloy, j)about 0.01-0.15 weight percent of the metal alloy, k) about 0.0001-0.075weight percent of the metal alloy, 1) about 0.0005-0.05 weight percentof the metal alloy, m) about 0.0005-0.18 weight percent of the metalalloy; n) about 0.001-0.05 weight percent of the metal alloy, and o)about 0.005-0.02 weight percent of the metal alloy. When titanium isadded to a tin and zinc metal alloy, the titanium is typically added asan alloy such as, but not limited to, a Zn—Ti alloy.

[0203] Zinc, if added to and/or included in the tin metal alloy, ispresent in amounts up to about 9-10 weight percent of the metal alloy.Higher weight percentages of zinc transforms the metal alloy to a tinand zinc metal alloy. In several aspects of the present invention, thezinc content of the tin metal alloy is a) up to about 7 weight percentof the tin metal alloy, b) up to about 1.5 weight percent of the tinmetal alloy, c) less than about 1 weight percent of the tin metal alloy,d) up to about 0.5 weight percent of the tin metal alloy, e) about0.001-0.5 weight percent of the tin metal alloy, and f) less than about0.2 weight percent of the tin metal alloy.

[0204] A general formulation of the corrosion resistant tin metal alloyby weight percent includes the following: Tin 75-99.99 Antimony  0-7.5Bismuth  0-1.7 Copper  0-5 Lead  0-10

[0205] A more specific formulation of the corrosion resistant tin metalalloy by weight percent includes the following: Tin 75-99.99 Aluminum 0-5 Antimony  0-7.5 Bismuth  0-1.7 Copper  0-5 Lead  0-10 Nickel  0-5Zinc  0-9

[0206] Another more specific formulation of the corrosion resistant tinmetal alloy by weight percent includes the following: Tin 90-99.99Aluminum  0-2 Antimony  0-2 Arsenic  0-0.05 Bismuth  0-1.5 Boron  0-0.1Cadmium  0-0.5 Carbon  0-1 Chromium  0-1 Copper  0-2 Iron  0-1 Lead  0-2Magnesium  0-1 Manganese  0-0.1 Molybdenum  0-0.1 Nickel  0-1 Silicon 0-0.5 Silver  0-0.1 Tellurium  0-0.05 Titanium  0-0.5 Vanadium  0-0.1Zinc  0-7

[0207] Still another more specific formulation of the tin metal alloy byweight percent includes the following: Tin 90-99.9 Aluminum  0-5Antimony  0-7.5 Arsenic  0-0.005 Bismuth  0-1.7 Boron  0-0.1 Cadmium 0-0.1 Carbon  0-1 Chromium  0-1 Copper  0-5 Iron  0-1 Lead  0-2Magnesium  0-5 Manganese  0-0.1 Molybdenum  0-0.1 Nickel  0-5 Silicon 0-0.5 Silver  0-0.005 Tellurium  0-0.05 Titanium  0-1 Vanadium  0-0.1Zinc  0-9

[0208] A few examples of the metal alloy composition by weight percentwhich have exhibited the desired characteristics as mentioned above areset forth as follows: Alloy Ingredients A B C D E F G H I J K L M N TinBal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal.Aluminum ≦0.01 ≦0.01 ≦0.05 0 0 ≦0.01 ≦0.01 0 0 ≦0.01 ≦0.01 ≦0.05 0.0 0.0Antimony ≦1 ≦0.1 ≦0.1 ≦0.05 ≦0.05 ≦0.1 ≦0.1 ≦0.05 ≦0.05 ≦1.0 ≦0.1 ≦0.1≦0.05 ≦0.05 Bismuth ≦0.05 ≦0.05 ≦0.01 ≦0.01 ≦0.01 ≦0.05 ≦0.01 ≦0.01≦0.01 ≦0.05 ≦0.05 ≦0.01 ≦0.01 ≦0.01 Copper ≦0.5 ≦0.05 0 1 0 ≦0.5 0 0 0≦0.5 ≦0.5 0.0 1.0 0.0 Iron ≦0.1 ≦0.005 0 0 0 ≦0.005 0 0 0 ≦0.1 ≦0.005≦0.0 ≦0.0 ≦0.0 Lead ≦1 ≦0.1 ≦0.1 ≦0.1 ≦2 ≦0.1 ≦0.1 ≦0.1 ≦0.05 ≦1.0 ≦0.1≦0.1 ≦0.1 ≦2.0 Nickel ≦0.005 ≦0.05 ≦0.05 ≦0.005 ≦0.05 0 0 0 0 ≦0.005≦0.0 ≦0.0 ≦0.005 ≦0.0 Zinc ≦1 ≦2 ≦3 ≦0.5 ≦1 ≦1 ≦1 ≦1 ≦1 ≦1 ≦2 ≦3 ≦0.5 ≦1

[0209] One formulation of the corrosion resistant tin metal alloyincludes by weight percent at least 75% tin; 0-1% aluminum; 0-2%antimony; 0-0.02% arsenic; 0-1.5% bismuth; 0-0.1% boron; 0-0.1% cadmium;0-0.5% carbon; 0-0.5% chromium; 0-2% copper; 0-1% iron; 0-2% lead;0-0.4% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel;0-0.05% silicon; 0-0.1% silver; 0-0.02% sulfur; 0-0.04% tellurium;0-0.15% titanium; 0-0.1% vanadium; and 0-9% zinc. Another formulation ofthe corrosion resistant tin metal alloy includes 90-99.9% tin; 0-0.5%aluminum; 0-2% antimony; 0-0.01% arsenic; 0-1.5% bismuth; 0-0.05% boron;0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2% copper; 0-1% iron;0-1% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1%nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.01% sulfur; 0-0.01%tellurium; 0-0.15% titanium; 0-0.1% vanadium; and 0-9% zinc. Stillanother formulation of the corrosion resistant tin metal alloy includesat least 90% tin; 0-1% aluminum; 0-2% antimony; 0-0.02% arsenic; 0-1.5%bismuth; 0-0.05% boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium;0-2% copper; 0-1% iron; 0-2% lead; 0-0.4% magnesium; 0-0.1% manganese;0-0.1% molybdenum; 0-1% nickel; 0-0.05% silicon; 0-0.05% silver; 0-0.02%sulfur; 0-0.04% tellurium; 0-0.15% titanium; 0-0.05% vanadium; and 0-5%zinc. Yet another formulation of the corrosion resistant tin metal alloyincludes 95-99.99% tin; 0-0.4% aluminum; 0-0.8% antimony; 0-0.005%arsenic; 0-0.5% bismuth; 0-0.1% boron; 0-0.05% cadmium; 0-0.1% carbon;0-0.05% chromium; 0-1% copper; 0-1% iron; 0-5% lead; 0-0.01% magnesium;0-0.01% manganese; 0-0.05% molybdenum; 0-0.9% nickel; 0-0.5% silicon;0-0.01% silver; 0-0.01% sulfur; 0-0.01% tellurium; 0-0.1% titanium;0-0.01% vanadium; and 0-2% zinc. Still yet another formulation of thecorrosion resistant tin metal alloy includes 95-99.99% tin; 0-0.4%aluminum; 0-0.8% antimony; 0-0.005% arsenic; 0-0.5% bismuth; 0-0.1%boron; 0-0.05% cadmium; 0-0.1% carbon; 0-0.05% chromium; 0-1% copper;0-0.5% iron; 0-0.5% lead; 0-0.01% magnesium; 0-0.01% manganese; 0-0.05%molybdenum; 0-0.9% nickel; 0-0.01% silicon; 0-0.01% silver; 0-0.01%sulfur; 0-0.01% tellurium; 0-0.1% titanium; 0-0.01% vanadium; and 0-2%zinc. A further formulation of the corrosion resistant tin metal alloyincludes 98-99.9% tin; 0-0.01% aluminum; 0-1% antimony and/or bismuth;0-0.1% copper; 0-0.05% iron; 0-0.5% lead; 0-0.05% magnesium; 0-0.05%manganese; 0-0.1% nickel; and 0-0.1% zinc. Yet a further formulation ofthe corrosion resistant tin metal alloy includes 98-99.99% tin; 0-0.1%aluminum; 0-1% antimony and/or bismuth; 0-0.001% arsenic; 0-0.001%boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.01% chromium; 0-0.1%copper; 0-0.05% iron; 0-0.05% lead; 0-0.001% magnesium; 0-0.001%manganese; 0-0.001% molybdenum; Q-0.9% nickel; 0-0.001% silicon;0-0.001% silver; 0-0.001% sulfur; 0-0.001% tellurium; 0-0.05% titanium;0-0.001% vanadium; and 0-1% zinc. Still yet a further formulation of thecorrosion resistant tin metal alloy includes at least 90% tin and0.01-0.1% lead. Another formulation of the corrosion resistant tin metalalloy includes 90-99.9% tin and 0.001-0.1% lead. Still anotherformulation of the corrosion resistant tin metal alloy includes 90-99.9%tin; 0-7.5% antimony; 0-1.7% bismuth; 0-2.7% copper; 0.001-0.1% lead;and O-1.5% zinc. Yet another formulation of the corrosion resistant tinmetal alloy includes 90-99.9% tin; less than 0.001% aluminum; 0-7.5%antimony; 0-1.7% bismuth; less than 0.05% cadmium; 0-2.7% copper;0.001-0.1% lead; and 0-1.5% zinc. Still yet another formulation of thecorrosion resistant tin metal alloy includes 90-99.9% tin; 0-2.5%antimony; 0-0.5% bismuth; 0-2.7% copper; 0-0.1% iron; 0.001-0.10% lead;and 0.5-1.5% zinc. A further formulation of the corrosion resistant tinmetal alloy includes 90-99.9% tin; 0-7.5% antimony; 0-1.7% bismuth;0-2.7% copper; 0-0.1% iron; 0.01-0.1% lead; and 0-1.5% zinc. Yet afurther formulation of the corrosion resistant tin metal alloy includes90-99.95% tin; 0-7.5% antimony; 0-1.7% bismuth; 0-2.7% copper; 0-1%iron; 0-0.5% lead; and 0-0.5% zinc. Still a further formulation of thecorrosion resistant tin metal alloy includes 90-99.95% tin; 0-7.5%antimony; 0-1.7% bismuth; 0-5% copper; 0-1% iron; 0-0.5% lead; and 0-7%zinc. Still yet a further formulation of the corrosion resistant tinmetal alloy includes 90-99.95% tin; 0-0.5% antimony and/or bismuth; 0-1%copper; 0-1% iron; 0-0.05% lead; and 0-1.5% zinc. Another formulation ofthe corrosion resistant tin metal alloy includes 90-99.95% tin;0.005-0.5% antimony; bismuth and/or copper; 0-0.05% lead; and 0-0.5%zinc. Still another formulation of the corrosion resistant tin metalalloy includes 90-99.9% tin; 0-5% aluminum; 0-7.5% antimony; 0-0.005%arsenic; 0-1.7% bismuth; 0-0.1% cadmium; 0-5% copper; 0-1% iron; 0-2%lead; 0-5% magnesium; 0-5% nickel; 0-0.005% silver; 0-1% titanium; and0-9% zinc. Yet another formulation of the corrosion resistant tin metalalloy includes 95-99.9% tin; 0-0.01% aluminum; 0-0.5% antimony; 0-0.5%bismuth; 0-0.005% iron; 0-0.1% lead; 0-0.1% nickel; and 0-2% zinc. Stillyet another formulation of the corrosion resistant tin metal alloyincludes 99-99.9% tin; 0-0.4% antimony; 0-0.2% bismuth; 0-0.001% iron;0-0.05% lead; 0-0.001% nickel; and 0-0.2% zinc. A further formulation ofthe corrosion resistant tin metal alloy includes 90-99.9% tin; 0-0.01%aluminum; 0-1% antimony; 0-0.05% bismuth; 0-0.5% copper; 0-0.1% iron;0-1% lead; 0-0.005% nickel; and 0-1% zinc. Yet a further formulation ofthe corrosion resistant tin metal alloy includes 90-99.9% tin; 0-0.5%aluminum; 0-2% antimony; 0-0.01% arsenic; 0-1.5% bismuth; 0-0.05% boron;0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2% copper; up to 1%iron; less than 1% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1%molybdenum; 0-1% nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.01% sulfur;0-0.01% tellurium; 0-0.15% titanium; 0-0.1% vanadium; and 0-9% zinc.Still a further formulation of the corrosion resistant tin metal alloyincludes 98-99.9% tin; 0-0.01% aluminum; 0-1% antimony and/or bismuth;0-0.1% copper; less than 0.05% iron; less than 0.5% lead; 0-0.05%magnesium; 0-0.05% manganese; 0-0.1% nickel; and 0-0.1% zinc. Still yeta further formulation of the corrosion resistant tin metal alloyincludes 99-99.9% tin; 0.001-0.8% antimony and/or bismuth; 0-0.02%copper; 0-0.001% iron; and 0-0.08% lead; 0-0.001% nickel; and 0-0.001%zinc. Another formulation of the corrosion resistant tin metal alloyincludes 90-99.9% tin; 0-5% aluminum; 0-7.5% antimony; 0-0.005% arsenic;0-1.7% bismuth; 0-0.005% cadmium; 0-5% copper; 0-1% iron; 0-2% lead;0-5% magnesium; 0-5% nickel; 0-0.005% silver; 0-1% titanium; and 0-9%zinc. Yet another formulation of the corrosion resistant tin metal alloyincludes 95-99.9% tin; 0-0.05% aluminum; 0-0.2% antimony; 0-0.1%bismuth; 0-0.1% copper; 0-0.1% iron; 0-0.2% lead; 0-0.1% nickel; and0-9% zinc. Still yet another formulation of the corrosion resistant tinmetal alloy includes 75-99.9% tin; 0-5% aluminum; 0-7.5% antimony;0-1.7% bismuth; 0-5% copper; 0-10% lead; 0-5% nickel; 0-0.5 titanium;and 0-9% zinc. A further formulation of the corrosion resistant tinmetal alloy includes 90-99.9% tin; 0-2% aluminum; 0-2% antimony; 0-0.05%arsenic; 0-1.5% bismuth; 0-0.1% boron; 0-0.5% cadmium; 0-1% carbon; 0-1%chromium; 0-2% copper; 0-1% iron; 0-2% lead; 0-1% magnesium; 0-0.1%manganese; 0-0.1% molybdenum; 0-1% nickel; 0-0.5% silicon; 0-0.1%silver; 0-0.05% tellurium; 0-0.5% titanium; 0-0.1% vanadium; and 0-7%zinc. Yet a further formulation of the corrosion resistant tin metalalloy includes at least 90% tin; 0-1% aluminum; 0-2% antimony; 0-0.02%arsenic; 0-1.5% bismuth; 0-0.5% boron; 0-0.1% cadmium; 0-0.5% carbon;0-0.5% chromium; 0-2% copper; 0-1% iron; 0-2% lead; 0-0.4% magnesium;0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel; 0-0.05% silicon;0-0.05% silver; 0-0.02% sulfur; 0-0.04% tellurium; 0-0.15% titanium;0-0.05% vanadium; and 0-5% zinc. Still a further formulation of thecorrosion resistant tin metal alloy includes 95-99.99% tin; 0-0.4%aluminum; 0-0.8% antimony; 0-0.005% arsenic; 0-0.5% bismuth; 0-0.1%boron; 0-0.05% cadmium; 0-0.1% carbon; 0-0.05% chromium; 0-1% copper;0-0.5% iron; 0-0.5% lead; 0-0.01% magnesium; 0-0.01% manganese; 0-0.05%molybdenum; 0-0.3% nickel; 0-0.01% silicon; 0-0.01% silver; 0-0.01%sulfur; 0-0.01% tellurium; 0-0.1% titanium; 0-0.01% vanadium; and 0-2%zinc. Still yet a further formulation of the corrosion resistant tinmetal alloy includes 98-99.99% tin; 0-0.1% aluminum; 0-1% antimonyand/or bismuth; 0-0.001% arsenic; 0-0.001% boron; 0-0.001% cadmium;0-0.01% carbon; 0-0.01% chromium; 0-0.1% copper; 0-0.05% iron; 0-0.05%lead; 0-0.001% magnesium; 0-0.001% manganese; 0-0.001% molybdenum;0-0.1% nickel; 0-0.001% silicon; 0-0.001% silver; 0-0.001% sulfur;0-0.001% tellurium; 0-0.05% titanium; 0-0.001% vanadium; and 0-1% zinc.Another formulation of the corrosion resistant tin metal alloy includesat least 75% tin; 0-1% aluminum; 0-2% antimony; 0-0.02% arsenic; 0-1.5%bismuth; 0-0.05% boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium;0-2% copper; 0-1% iron; 0-2% lead; 0-0.4% magnesium; 0-0.1% manganese;0-0.1% molybdenum; 0-1% nickel; 0-0.05% silicon; 0-0.1% silver; 0-0.02%sulfur; 0-0.04% tellurium; 0-0.15% titanium; 0-0.1% vanadium; and 0-9%zinc. Yet another formulation of the corrosion resistant tin metal alloyincludes 95-99.99% tin; 0-0.4% aluminum; 0-0.8% antimony; 0-0.005%arsenic; 0-0.5% bismuth; 0-0.1% boron; 0-0.05% cadmium; 0-0.1% carbon;0-0.05% chromium; 0-1% copper; 0-1% iron; 0-5% lead; 0-0.01% magnesium;0-0.01% manganese; 0-0.05% molybdenum; 0-0.9% nickel; 0-0.5% silicon;0-0.01% silver; 0-0.01% sulfur; 0-0.01% tellurium; 0-0.1% titanium;0-0.01% vanadium; and 0-2% zinc. Still another formulation of thecorrosion resistant tin metal alloy includes 98-99.99% tin; 0-0.1%aluminum; 0-1% antimony and/or bismuth; 0-0.001% arsenic; 0-0.001%boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.01% chromium; 0-0.1%copper; 0-0.05% iron; 0-0.05% lead; 0-0.001% magnesium; 0-0.001%manganese; 0-0.001% molybdenum; 0-0.9% nickel; 0-0.001% silicon;0-0.001% silver; 0-0.001% sulfur; 0-0.001% tellurium; 0-0.05% titanium;0-0.001% vanadium; and 0-1% zinc. Still yet another formulation of thecorrosion resistant tin metal alloy includes 90-99.9% tin; 0-0.5%antimony; 0-1.5% bismuth; 0.00-1% lead; and 0-0.001% zinc. A furtherformulation of the corrosion resistant tin metal alloy includes 90-99.9%tin; 0-0.75% antimony; 0-0.5% bismuth; 0-0.1% iron; 0-1% lead; and0-0.5% zinc. Yet a further formulation of the corrosion resistant tinmetal alloy includes 90-99.9% tin; 0-7.5% antimony; 0-2.7% copper; and0-1% lead. Still a further formulation of the corrosion resistant tinmetal alloy includes 90-99.9% tin; 0-2.5% antimony; 0-2% copper; 0-1%lead; and 0-0.5% zinc. Still yet a further formulation of the corrosionresistant tin metal alloy includes 90-99.9% tin; 0-0.75% antimony;0-0.5% bismuth; 0-0.1% iron; 0-1% lead; and 0-0.5% zinc. Anotherformulation of the corrosion resistant tin metal alloy includes 90-99.9%tin; 0-1% antimony; 0-0.5% bismuth; 0-0.1% iron; and 0-1% lead. Stillanother of the corrosion resistant tin metal alloy includes 90-99.9%tin; 0-0.5% bismuth; 0-0.1% iron; and 0-1% lead. Yet another formulationof the corrosion resistant tin metal alloy includes 90-99.9% tin;0-0.75% antimony; 0-0.5% bismuth; 0-0.01% iron; 0.001-0.05% lead; and0-0.5% zinc. Still yet another formulation of the corrosion resistanttin metal alloy includes 90-99.9% tin; 0-0.5% antimony; 0-1.7% bismuth;0-0.02% lead; and 0-0.001% zinc. A further formulation of the corrosionresistant tin metal alloy includes 90-99.9% tin; 0-0.75% antimony;0-0.5% bismuth; 0-0.005% cobalt; 0-2.7% copper; 0-0.1% iron; 0-0.05%lead; 0-0.005% nickel; 0-0.001% silver; 0-0.001% sulfur; and 0-0.5%zinc. Still a further formulation of the corrosion resistant tin metalalloy includes 90-99.9% tin; 0-7.5% antimony; and 0-2.7% copper. Yet afurther formulation of the corrosion resistant tin metal alloy includes90-99.9% tin; 0-2.5% antimony; 0-2% copper; and 0-0.5% zinc. Still yet afurther formulation of the corrosion resistant tin metal alloy includes90-99.9% tin; 0-0.5% antimony; 0-1.5% bismuth; 0-0.005% cobalt; 0-0.02%lead; 0-0.005% nickel; 0-0.001% silver; 0-0.001% sulfur; and 0-0.001%zinc. Another formulation of the corrosion resistant tin metal alloyincludes 90-99.9% tin and 0-0.1% lead. Still another formulation of thecorrosion resistant tin metal alloy includes 90-99.9% tin and 0-0.01%lead. Yet another formulation of the corrosion resistant tin metal alloyincludes 90-99.9% tin; 0-5.5% antimony; 0-0.5% aluminum; 0-1.7% bismuth;0-2.7% copper; 0-0.4% magnesium; 0-1% nickel; and 0-0.15% titanium.Still yet another formulation of the corrosion resistant tin metal alloyincludes 90-99.9% tin; 0-0.75% antimony; 0-0.5% bismuth; 0-0.005%cobalt; 0-2.7% copper; 0-0.1% iron; 0-0.05% lead; 0-0.005% nickel;0-0.001% silver; 0-0.001% sulfur; and 0-0.5% zinc. A further formulationof the corrosion resistant tin metal alloy includes 90-95% tin; 0-0.25%aluminum; 0-1.5% copper; 0-0.02% chromium; 0-0.01% iron; 0-0.01% lead;0-0.01% manganese; 0-0.018% titanium; and 0-9% zinc. Still a furtherformulation of the corrosion resistant tin metal alloy includes 0-2.5%antimony, 0-0.5% bismuth, 0-2.7% copper, 0-0.1% iron, 0.001-0.1% lead,0.5-1.5% zinc and the remainder tin. Another formulation of thecorrosion resistant tin metal alloy includes 90-99.9% tin; 0-7.2%antimony; 0-1.7% bismuth; 0-2.7% copper; 0-0.1% iron; 0.001-0. 1% lead;and 0-1.5% zinc. Still another formulation of the corrosion resistanttin metal alloy includes at least about 95% tin; 0.001-0.1% lead, and atleast about 0.5% stabilizer. Yet another formulation of the corrosionresistant tin metal alloy includes 0-2.5% antimony, 0-0.5% bismuth,0-2.7% copper, 0-0.1% iron, 0.001-0.1% lead, 0-1.5% zinc and theremainder tin. Still yet another formulation of the corrosion resistanttin metal alloy includes 90-99.95% tin; 0-7.2% antimony; 0-1.7% bismuth;0-2.7% copper; 0-0.1% iron; 0.001-0.1% lead; and 0-0.5% zinc. A furtherformulation of the corrosion resistant tin metal alloy includes90-99.95% tin; 0-7.2% antimony; 0-1.7% bismuth; and 0.001-0.05% lead.Still a further formulation of the corrosion resistant tin metal alloyincludes 95-99.9% tin; 0-0.1% aluminum; 0-1% antimony; 0-0.5% bismuth;0-0.5% copper; 0-0.1% iron; 0-0.5% lead; 0-0.1% nickel; and 0-0.2% zinc.Still yet a further formulation of the corrosion resistant tin metalalloy includes 98-99.9% tin; 0-0.4% antimony; 0-0.2% bismuth; 0-0.1%copper; 0-0.01% iron; 0-0.05% lead; 0-0.01% nickel; and 0-0.05% zinc.Another formulation of the corrosion resistant tin metal alloy includes75-99.99% tin; 0-5% aluminum; 0-7.5% antimony; 0-1.7% bismuth; 0-5%copper; 0-10% lead; 0-5% nickel; 0-0.5% titanium; and 0-9% zinc. Stillanother formulation of the corrosion resistant tin metal alloy includes98-99% tin; 0-0.1% aluminum; 0-1% antimony and/or bismuth; 0-0.001%arsenic; 0-0.001% boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.01%chromium; 0-0.1% copper; 0-0.05% iron; 0-0.05% lead; 0-0.001% magnesium;0-0.001% manganese; 0-0.001% molybdenum; 0-0.1% nickel; 0-0.001%silicon; 0-0.001% silver; 0-0.001% sulfur; 0-0.001% tellurium; 0-0.05%titanium; 0-0.001% vanadium; and 0-1% zinc. Yet another formulation ofthe corrosion resistant tin metal alloy includes 50-99.999% tin; 0-7.5%aluminum; 0-2% antimony; 0-0.05% arsenic; 0-0.1% boron; 0-1.7% bismuth;0-0.5% cadmium; 0-1% carbon; 0-1% chromium; 0-5% copper; 0-1% iron;0-10% lead; 0-1% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-5%nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.05% tellurium; 0-0.5%titanium; 0-0.1% vanadium; and 0-9% zinc. Yet another formulation of thecorrosion resistant tin metal alloy includes 90-99.999% tin; 0-7.5%aluminum; 0-2% antimony; 0-0.05% arsenic; 0-0.1% boron; 0-1.7% bismuth;0-0.5% cadmium; 0-1% carbon; 0-1% chromium; 0-5% copper; 0-1% iron;0-10% lead; 0-1% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-5%nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.05% tellurium; 0-0.5%titanium; 0-0.1% vanadium; and 0-9% zinc. Still another formulation ofthe corrosion resistant tin metal alloy includes 75-99.999% tin; 0-7.5%aluminum; 0-2% antimony; 0-0.05% arsenic; 0-0.1% boron; 0-1.7% bismuth;0-0.5% cadmium; 0-1% carbon; 0-1% chromium; 0-5% copper; 0-1% iron;0-10% lead; 0-1% magnesium, 0-0.1% manganese; 0-0.1% molybdenum; 0-5%nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.05% tellurium; 0-0.5%titanium; 0-0.1% vanadium; and 0-10% zinc. Yet another formulation ofthe corrosion resistant tin metal alloy includes 75-99.999% tin; 0-7.5%aluminum; 0.001-5% antimony, bismuth, cadmium and/or copper; 0-2% lead;0-1% nickel; and 0-10% zinc. Still yet another formulation of thecorrosion resistant tin metal alloy includes 95-99.999% tin; 0-2%aluminum; 0.001-2% antimony, bismuth, cadmium and/or copper; 0-1% lead;0-1% nickel; and 0-2% zinc. Still another formulation of the corrosionresistant tin metal alloy includes 98-99% tin; 0-0.1% aluminum; 0-1%antimony and/or bismuth; 0-0.001% arsenic; 0-0.001% boron; 0-0.001%cadmium; 0-0.01% carbon; 0-0.01% chromium; 0-0.1% copper; 0-0.05% iron;0-0.05% lead; 0-0.001% magnesium; 0-0.001% manganese; 0-0.001%molybdenum; 0-0.9% nickel; 0-0.001% silicon; 0-0.001% silver; 0-0.001%sulfur; 0-0.001% tellurium; 0-0.05% titanium; 0-0.001% vanadium; and0-1% zinc.

[0210] A general formulation of the corrosion resistant tin and zincmetal alloy by weight percent includes the following: Tin 15-90 Zinc10-85 Antimony   0-7.5 Bismuth 0-5 Copper 0-5

[0211] One more specific formulation of the corrosion resistant tin andzinc metal alloy by weight percent includes the following: Tin 15-90Zinc 10-85 Aluminum 0-5 Antimony   0-7.5 Bismuth 0-5 Cadmium 0-1 Copper0-5 Nickel 0-5

[0212] Another specific formulation of the corrosion resistant tin andzinc metal alloy by weight percent includes the following: Tin 20-80Zinc 20-80 Aluminum  0-2 Antimony  0-1 Arsenic  0-0.05 Bismuth  0-1Boron  0-0.1 Cadmium  0-0.1 Carbon  0-0.5 Chromium  0-0.5 Copper  0-2Iron  0-1 Lead  0-1 Magnesium  0-1 Manganese  0-0.1 Molybdenum  0-0.1Nickel  0-1 Silicon  0-0.5 Silver  0-0.1 Tellurium  0-0.05 Titanium 0-0.5 Vanadium  0-0.1

[0213] Still another specific formulation of the corrosion resistant tinand zinc metal alloy by weight percent includes the following: Tin 30-85Zinc 15-70 Aluminum  0-1 Antimony  0-1 Arsenic  0-0.01 Bismuth  0-1Boron  0-0.1 Cadmium  0-0.1 Carbon  0-0.5 Chromium  0-0.1 Copper  0-1Iron  0-0.1 Lead  0-0.1 Magnesium  0-1 Manganese  0-0.01 Molybdenum 0-0.1 Nickel  0-0.1 Silicon  0-0.5 Silver  0-0.01 Tellurium  0-0.05Titanium  0-0.05 Vanadium  0-0.1

[0214] Yet another specific formulation of the corrosion-resistant tinand zinc metal alloy by weight percent includes the following: Tin 70-90Zinc 10-30 Aluminum 0.001-0.01  Antimony 0.001-0.8  Copper 0.001-0.02 Bismuth 0.001-0.005 Boron   0-0.05 Silver    0-0.005 Carbon   0-0.05Chromium   0-0.05 Iron    0-0.005 Magnesium   0-0.05 Manganese   0-0.01Molybdenum   0-0.05 Silicon   0-0.05 Tellurium   0-0.01 Titanium  0-0.05 Vanadium   0-0.05 Arsenic    0-0.005 Cadmium   0-0.01 Nickel   0-0.005 Lead 0.01-0.1

[0215] Still yet another specific formulation of the corrosion-resistanttin and zinc metal alloy by weight percent includes the following: Tin79.5-81.5 Zinc 18.5-20.5 Aluminum 0.002-0.008 Antimony 0.6-0.7 Arsenic   0-0.001 Bismuth 0.002-0.005 Cadmium    0-0.001 Copper 0.005-0.02 Iron    0-0.001 Lead 0.02-0.08 Nickel    0-0.001 Silver    0-0.001

[0216] Examples of the tin and zinc metal alloy composition by weightpercent include: Ingredients A B C D E F G H I J K L M N O E Zinc 10 1520 25 30 35 40 45 50 55 60 65 70 75 80 85 Tin 90 85 80 75 70 65 60 55 5045 40 35 30 25 20 15 Aluminum ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 Antimony ≦0.5 ≦0.5 ≦0.5 ≦0.5≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 Bismuth ≦0.5≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5≦0.5 Copper ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.05 ≦0.5≦0.5 ≦0.5 ≦0.5 ≦0.5 Lead ≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1

[0217] One formulation of the corrosion resistant tin and zinc metalalloy includes by weight percent 20-80% tin; 20-80% zinc; 0-1% aluminum;0-2% antimony; 0-0.02% arsenic; 0-1.5% bismuth; 0-0.1% boron; 0-0.1%cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2% copper; 0-1% iron; 0-1%lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1%nickel; 0-0.5% silicon; 0-0.05% silver; 0-0.02% sulfur; 0-0.04%tellurium; 0-0.15% titanium; and 0-0.05% vanadium. Another formulationof the corrosion resistant tin and zinc metal alloy includes 30-70% tin;30-70% zinc; 0-0.4% aluminum; 0-0.8% antimony; 0-0.005% arsenic; 0-0.5%bismuth; 0-0.05% boron; 0-0.05% cadmium; 0-0.1% carbon; 0-0.1% chromium;0-1% copper; 0-0.6% iron; 0-0.5% lead; 0-0.1% magnesium; 0-0.1%manganese; 0-0.05% molybdenum; 0-0.9% nickel; 0-0.01% silicon; 0-0.01%silver; 0-0.01% sulfur; 0-0.01% tellurium; 0-0.1% titanium; and 0-0.01%vanadium; and the tin plus zinc content is at least 90 weight percent ofthe alloy. Still another formulation of the corrosion resistant tin andzinc metal alloy includes 40-60% tin; 40-60% zinc; 0-0.4% aluminum; 0-1%antimony and/or bismuth; 0-0.001% arsenic; 0-0.01% boron; 0-0.005%cadmium; 0-0.05% carbon; 0-0.05% chromium; 0-0.1% copper; 0-0.05% iron;0-0.1% lead; 0-0.01% magnesium; 0-0.01% manganese; 0-0.01% molybdenum;0-0.9% nickel; 0-0.001% silicon; 0-0.001% silver; 0-0.001% sulfur;0-0.001% tellurium; 0-0.05% titanium; and 0-0.001% vanadium; and the tinplus zinc content is at least 95 weight percent of the alloy. Yetanother formulation of the corrosion resistant tin and zinc metal alloyincludes 45-55% zinc; 45-55% tin; 0-0.4% aluminum; 0-0.8% antimonyand/or bismuth; 0-0.001% arsenic; 0-0.001% boron; 0-0.001% cadmium;0-0.01% carbon; 0-0.05% copper; 0-0.001 iron; 0-0.08% lead; 0-0.001%magnesium; 0-0.001% manganese; 0-0.001% molybdenum; 0-0.9% nickel;0-0.001% silicon; 0-0.005% silver; 0-0.001% sulfur; 0-0.001% tellurium;0-0.05% titanium and 0-0.001% vanadium; and the tin content plus thezinc content is at least 99% of the alloy. Still yet another formulationof the corrosion resistant tin and zinc metal alloy includes 30-85% tin;15-70% zinc; 0-0.5% aluminum; 0-2% antimony; 0-0.01% arsenic; 0-1.5%bismuth; 0-0.05% boron; 0-0.1% cadmium; 0-0.1% carbon; 0-0.1% chromium;0-2% copper; 0-1% iron; 0-0.5% lead; 0-0.4% magnesium; 0-0.1% manganese;0-0.05% molybdenum; 0-1% nickel; 0-0.5% silicon; 0-0.05% silver; 0-0.01%sulfur; 0-0.01% tellurium; 0-0.15% titanium; and 0-0.05% vanadium. Afurther formulation of the corrosion resistant tin and zinc metal alloyincludes 30-65% tin; 35-70% zinc; 0-0.1% aluminum; 0-1% antimony and/orbismuth; 0-0.05% arsenic; 0-0.01% cadmium; 0-0.5% copper; less than0.05% iron; less than 0.1% lead; 0-0.1% magnesium; 0-0.1% manganese;0-0.5% nickel; 0-0.05% silver; 0-0.05% titanium; and the tin plus zinccontent is at least 98% of the metal alloy. Still a further formulationof the corrosion resistant tin and zinc metal alloy includes 40-60% tin;40-60% zinc; 0-0.4% aluminum; 0-0.8% antimony and/or bismuth; 0-0.005%arsenic; 0-0.005% cadmium; 0-0.2% copper; 0-0.05% iron; 0-0.1% lead;0-0.001% magnesium; 0-0.001% manganese; 0-0.05% nickel; 0-0.005% silver;0-0.05% titanium; and the tin plus zinc content is at least 99% of themetal alloy. Yet a further formulation of the corrosion resistant tinand zinc metal alloy includes 60-90% tin; 10-40% zinc; 0-0.5% aluminum;0-2% antimony; 0-0.01% arsenic; 0-1.5% bismuth; 0-0.05% boron; 0-0.1%cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2% copper; up to 1% iron;less than 0.5% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1%molybdenum; 0-1% nickel; 0-0.5% silicon; 0-0.01% silver; 0-0.01% sulfur;0-0.01% tellurium; 0-0.15% titanium; and 0-0.1% vanadium. Still yet afurther formulation of the corrosion resistant tin and zinc metal alloyincludes 70-90% tin; 10-30% zinc; 0-0.1% aluminum; 0-1% antimony and/orbismuth; 0-0.05% arsenic; 0-0.01% cadmium; 0-0.5% copper; less than0.05% iron; less than 0.1% lead; 0-0.1% magnesium; 0-0.1% manganese;0-0.5% nickel; 0-0.05% silver; 0-0.05% titanium; and the tin plus zinccontent is at least 95% of the metal alloy. Yet a further formulation ofthe corrosion resistant tin and zinc metal alloy includes 75-85% tin;15-25% zinc; 0.001-0.01% aluminum; 0.001-0.8% antimony and/or bismuth;0-0.005% arsenic; 0-0.001% cadmium; 0.005-0.02% copper; 0-0.001 iron;0.01-0.08% lead; 0-0.001% magnesium; 0-0.001% manganese; 0-0.001%nickel; 0-0.01 silver; 0-0.001% titanium; and the tin plus zinc contentis at least 98% of the metal alloy coating. Another formulation of thecorrosion resistant tin and zinc metal alloy includes 15-35% tin; 65-85%zinc; 0-7.5% antimony; 0-1.7% bismuth. Yet another formulation of thecorrosion resistant tin and zinc metal alloy includes 15-35% tin; 65-85%zinc; and 0.01-0.5% antimony and/or bismuth. Still another formulationof the corrosion resistant tin and zinc metal alloy includes 15-35% tin;65-85% zinc; 0.01-0.5% antimony and/or bismuth; and less than 2% copperand/or iron. Still yet another formulation of the corrosion resistanttin and zinc metal alloy includes 15-35% tin; 65-85% zinc; 0-0.5%antimony; 0-0.5% bismuth; and less than 0.01% lead. A furtherformulation of the corrosion resistant tin and zinc metal alloy includes15-35% tin; 65-85% zinc; 0-0.5% antimony; 0-0.5% bismuth; less than 2%copper and/or iron; and less than 0.01% lead. Yet a further formulationof the corrosion resistant tin and zinc metal alloy includes 15-35% tin;65-85% zinc; 0-7.5% antimony; 0-1.7% bismuth; 0-2% copper; 0-0.1% iron;and 0-0.05% lead. Another formulation of the corrosion resistant tin andzinc metal alloy includes 70-90% tin; 10-30% zinc; 0-7.5% antimony;0-1.7% bismuth; 0-2% copper; 0-0.1% iron; and 0-0.05% lead. Stillanother formulation of the corrosion resistant tin and zinc metal alloyincludes 80-90% tin; 10-20% zinc; 0-7.5% antimony; 0-1.7% bismuth; 0-2%copper; 0-0.1% iron; and 0-0.05% lead. Yet another formulation of thecorrosion resistant tin and zinc metal alloy includes 70-90% tin; 10-30%zinc; 0-2.5% antimony; 0-0.5% bismuth; 0-2% copper; 0-0.1% iron; and0-0.05% lead. Still yet another formulation of the corrosion resistanttin and zinc metal alloy includes 70-90% tin; 10-30% zinc; 0.5-7.5%antimony; 0.5-1.7% bismuth; 0-2% copper; 0-0.1% iron; and 0-0.05% lead.A further formulation of the corrosion resistant tin and zinc metalalloy includes 80-90% tin; 10-20% zinc; 0-7.5% antimony; 0-1.7% bismuth;0-2% copper; 0-0.1% iron; and 0-0.01% lead. A further formulation of thecorrosion resistant tin and zinc metal alloy includes 15-70% tin; 30-85%zinc; 0-7.5% antimony; 0-1.7% bismuth; 0-5% copper; 0-0.1% iron; 0-0.05%lead; and 0-5% nickel. Yet a further formulation of the corrosionresistant tin and zinc metal alloy includes 15-70% tin; 30-85% zinc;0-0.5% antimony; 0-0.5% bismuth; 0-2% copper; 0-0.1% iron; 0-0.01% lead;and 0-1% nickel. Still a further formulation of the corrosion resistanttin and zinc metal alloy includes 35-70% tin; 30-65% zinc; 0-0.5%antimony; 0-0.5% bismuth; 0-2% copper; 0-0.1% iron; 0-0.05% lead; and0-1% nickel. Still yet a further formulation of the corrosion resistanttin and zinc metal alloy includes 45-55% tin; 45-55% zinc; 0-0.5%antimony and/or bismuth; 1-1.5% copper; 0-0.1% iron; 0-0.01% lead;0.3-0.9% nickel; and the tin content plus zinc content at least 95% ofthe metal alloy. Another formulation of the corrosion resistant tin andzinc metal alloy includes 20-90% tin; 10-80% zinc; 0-0.5% aluminum; 0-1%antimony; 0-2.7% copper; and 0-0.15% titanium. Still another formulationof the corrosion resistant tin and zinc metal alloy includes 20-90% tin;10-80% zinc; 0-0.3% aluminum; 0-5.5% antimony; and 0-1% copper. Yetanother formulation of the corrosion resistant tin and zinc metal alloyincludes 20-90% tin; 10-80% zinc; 0-5% aluminum; 0-5.5% antimony; 0-1.7%bismuth; 0-5% copper; 0-0.1% iron; 0-0.05% lead; 0-5% magnesium; 0-5%nickel; and 0-1% titanium. Still another formulation of the corrosionresistant tin and zinc metal alloy includes 20-75% tin; 25-80% zinc;0-1% aluminum; 0-5.5% antimony; 0-1.7% bismuth; 0-2.7% copper; 0-0.1%iron; 0-0.05% lead; 0-1% magnesium; 0-1% nickel; and 0-0.5% titanium.Still yet another formulation of the corrosion resistant tin and zincmetal alloy includes 20-80% tin; 20-80% zinc; 0-0.5% aluminum; 0-5.5%antimony; 0-1.5% bismuth; 0-2.7% copper; 0-0.1% iron; 0-0.01% lead;0-0.4% magnesium; 0-1% nickel; and 0-0.15% titanium. A furtherformulation of the corrosion resistant tin and zinc metal alloy includes35-70% tin; 30-65% zinc; 0-0.3% aluminum; 0.05-1% antimony and/orbismuth; 0-1% copper; 0-0.1% iron; 0-0.01% lead; 0-0.4% magnesium;0-0.7% nickel; 0-0.15% titanium; and the tin plus zinc content is atleast 90% of the metal alloy. Yet a further formulation of the corrosionresistant tin and zinc metal alloy includes 15-90% tin; 10-85% zinc;0-5% aluminum; 0-7.5% antimony; 0-1.7% bismuth; 0-5% copper; 0-1% iron;0-1% lead; 0-5% magnesium; 0-5% nickel; and 0-1% titanium. Still yet afurther formulation of the corrosion resistant tin and zinc metal alloyincludes 10-70% tin; 30-90% zinc; 0-0.25% aluminum; 0-0.02% chromium;0-1.5% copper; 0-0.01% iron; 0-0.01% lead; 0-0.01% magnesium; and0-0.18% titanium. Another formulation of the corrosion resistant tin andzinc metal alloy includes 10-70% tin; 30-90% zinc; 0-0.25% aluminum;0-0.02% chromium; 0-1.5% copper; 0-0.01% iron; 0-0.01% lead; 0-0.01%magnesium; and 0-0.18% titanium. Still another formulation of thecorrosion resistant tin and zinc metal alloy includes 15-90% tin; 10-85%zinc; 0-0.01% aluminum; 0-1% antimony; 0-0.005% arsenic; 0-0.01%bismuth; 0-0.05% cadmium; 0-0.05% copper; 0-0.005% iron; 0-0.1% lead;0-0.005% nickel; and 0-0.005% silver. Yet another formulation of thecorrosion resistant tin and zinc metal alloy includes 70-90% tin; 10-30%zinc; 0-0.01% aluminum; 0.001-0.8% antimony; 0-0.005% arsenic;0.001-0.005% bismuth; 0-0.01% cadmium; 0-0.02% copper; 0-0.005% iron;0-0.1% lead; 0-0.005% nickel; and 0-0.005% silver. Still yet anotherformulation of the corrosion resistant tin and zinc metal alloy includes79.5-81.5% tin; 18.5-20.5% zinc; 0.002-0.008% aluminum; 0.6-0.7%antimony; 0-0.001% arsenic; 0.002-0.005% bismuth; 0-0.001% cadmium;0.005-0.02% copper; 0-0.001% iron; 0.02-0.08% lead; 0-0.001% nickel; and0-0.001% silver. A further formulation of the corrosion resistant tinand zinc metal alloy includes 70-90% tin; 10-30% zinc; 0-0.01% aluminum;0-1% antimony; 0-0.005% arsenic; 0-0.01% bismuth; 0-0.01% cadmium;0-0.5% copper; 0-0.005% iron; 0-0.1% lead; 0-0.005% nickel; and 0-0.005%silver. Yet further formulation of the corrosion resistant tin and zincmetal alloy includes 60-90% tin; 10-40% zinc; 0-0.5% aluminum; 0-2%antimony; 0-0.01% arsenic; 0-1.5% bismuth; 0-0.05% boron; 0-0.1%cadmium; 0-0.5% carbon; 0.0-0.5% chromium; 0-2% copper; up to 1% iron;less than 0.5% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1%molybdenum; 0-1% nickel; 0-0.5% silicon; 0-0.01% silver; 0-0.01% sulfur;0-0.01% tellurium; 0-0.15% titanium; and 0-0.1% vanadium. Still afurther formulation of the corrosion resistant tin and zinc metal alloyincludes 70-90% tin; 10-30% zinc; 0-0.1% aluminum; 0-1% antimony and/orbismuth; 0-0.05% arsenic; 0-0.01% cadmium; 0-0.5% copper; less than0.05% iron; less than 0.1% lead; 0-0.1% magnesium; 0-0.1% manganese;0-0.5% nickel; 0-0.5% silicon; 0-0.05% silver; 0-0.05% titanium; and thetin plus zinc content is at least 95% of the metal alloy. Still yet afurther formulation of the corrosion resistant tin and zinc metal alloyincludes 75-85% tin; 15-25% zinc; 0.001-0.01% aluminum; 0.001-0.8%antimony and/or bismuth; 0-0.005% arsenic; 0-0.001% cadmium; 0.005-0.02%copper; 0-0.0015% iron; 0.01-0.08% lead; 0-0.001% magnesium; 0-0.001%manganese; 0-0.001% nickel; 0-0.5% silicon; 0-0.01% silver; 0-0.001%titanium; and the tin plus zinc content is at least 98% of the metalalloy. Another formulation of the corrosion resistant tin and zinc metalalloy includes 15-90% tin; 10-85% zinc; 0-2% aluminum; 0-2% antimony;0-1.7% bismuth; 0-2% copper; 0-1% iron; 0-0.5% lead; 0-2% magnesium;0-2% nickel; and 0-1% titanium. Still another formulation of thecorrosion resistant tin and zinc metal alloy includes 15-90% tin; 10-85%zinc; 0-1% aluminum; 0-2% antimony; 0-1.7% bismuth; 0-2% copper; 0-1%iron; 0-0.5% lead; 0-1% magnesium; 0-1% nickel; and 0-0.5% titanium. Yetanother formulation of the corrosion resistant tin and zinc metal alloyincludes 20-90% tin; 10-80% zinc; 0-0.51% aluminum; 0-2% antimony;0-1.5% bismuth; 0-0.01% boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.5%chromium; 0-2% copper; 0-1% iron; 0-0.5% lead; 0-0.4% magnesium; 0-0.1%manganese; 0-0.1% molybdenum; 0-1% nickel; 0-0.5% silicon; and 0-0.15%titanium; and 0-0.1% vanadium. Still another formulation of thecorrosion resistant tin and zinc metal alloy includes 20-65% tin; 30-80%zinc; 0-0.3% aluminum; 0-1% antimony and/or bismuth; 0-1% copper; 0-0.6%iron; 0-0.5% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.7% nickel;0-0.15% titanium; and the tin plus zinc content is at least 95% of themetal alloy. Still yet another formulation of the corrosion resistanttin and zinc metal alloy includes 20-50% tin; 50-80% zinc; 0-0.3%aluminum; 0.005-0.5% antimony and/or bismuth; 0-0.05% cadmium; 0-0.2%copper; 0-0.6% iron; 0-0.4% lead; 0-0.1% magnesium; 0-0.05% manganese;0-0.1% nickel; 0-0.1% silicon; 0-0.15% titanium; and the tin plus zinccontent is at least 95% of the metal alloy. A further formulation of thecorrosion resistant tin and zinc metal alloy includes 20-70% tin; 30-75%zinc; 0.0005-2% aluminum; 0.001-2% antimony; 0.0001-1% bismuth; 0-2%copper; 0-0.5% lead; and 0.0001-0.1% titanium. Yet a further formulationof the corrosion resistant tin and zinc metal alloy includes 40-60% tin;40-60% zinc; 0.0005-0.75% aluminum; 0.001-1% antimony; 0-0.01% arsenic;0.0001-0.2% bismuth; 0-0.01% cadmium; 0.001-1% copper; 0-0.01% chromium;0-0.1% iron; 0-0.1% lead; 0-0.01% manganese; 0-0.2% nickel; 0-0.01%silver; and 0.0005-0.05% titanium. Still yet a further formulation ofthe corrosion resistant tin and zinc metal alloy includes 25-70% tin;30-75% zinc; 0-0.5% aluminum; 0-0.5% copper; 0-0.1% lead; and 0-0.05%titanium. Another formulation of the corrosion resistant tin and zincmetal alloy includes 30-70% tin; 30-70% zinc; 0.0001-0.5% aluminum;0.001-2% antimony; 0-0.01% arsenic; 0.0001-1% bismuth; 0-0.01% boron;0-0.01% cadmium; 0-0.05% carbon; 0-0.05% chromium; 0-2% copper; 0-0.1%iron; 0-0.5% lead; 0-0.01% magnesium; 0-0.01% manganese; 0-0.01%molybdenum; 0-1% nickel; 0-0.01% silicon; 0-0.01% silver; 0-0.01%sulfur; 0-0.01% tellurium; 0.0001-0.1% titanium; and 0-0.01% vanadium.Still another formulation of the corrosion resistant tin and zinc metalalloy includes 40-60% tin; 40-60% zinc; 0.0005-0.4% aluminum; 0.01-0.8%antimony; 0-0.005% arsenic; 0.001-0.05% bismuth; 0-0.005% cadmium;0.005-0.5% copper; 0-0.05% iron; 0-0.1% lead; 0-0.05% nickel; 0-0.005%silver; and 0.0005-0.05% titanium. Yet another formulation of thecorrosion resistant tin and zinc metal alloy includes 48-52% tin; 48-52%zinc; 0.005-0.24% aluminum; 0.05-0.64% antimony; 0-0.001% arsenic;0.002-0.005% bismuth; 0-0.001% cadmium; 0.01-0.3% copper; 0-0.016% iron;0-0.08% lead; 0-0.001% nickel; 0-0.001 silver; and 0.001-0.02% titanium.Yet another formulation of the corrosion resistant tin and zinc metalalloy includes 15-90% tin; 10-85% zinc; 0-5% aluminum; 0-5% antimony;0-5% bismuth; 0-1% cadmium; 0-5% copper; 0-1% iron; 0-1% lead; and 0-1%nickel. Still another formulation of the corrosion resistant tin andzinc metal alloy includes 30-85% tin; 15-70% zinc; 0-1% antimony; 0-0.1%arsenic; 0-1% bismuth; 0-0.1% cadmium; 0-1% copper; 0-0.1% iron; 0-0.1%lead; 0-0.1% manganese; 0-0.1% nickel; 0-0.1% silver; and 0-0.05%titanium. Still yet another formulation of the corrosion resistant tinand zinc metal alloy includes 30-80% tin; 20-70% zinc; 0-0.5% aluminum;0-0.5% antimony; 0-0.5% bismuth; 0-0.5% copper; and 0-0.1% lead. Afurther formulation of the corrosion resistant tin and zinc metal alloyincludes 30-85% tin; 15-70% zinc; 0-0.5% aluminum; 0-2 antimony; 0-0.01%arsenic; 0-1.5% bismuth; 0-0.05% boron; 0-0.1% cadmium; 0-0.1% carbon;0-0.1% chromium; 0-2% copper; 0-1% iron; 0-0.5% lead; 0-0.4% magnesium;0-0.1% manganese; 0-0.05% molybdenum; 0-1% nickel; 0-0.5% silicon;0-0.05% silver; 0-0.01% tellurium; 0-0.15% titanium; and 0-0.05%vanadium. Yet a further formulation of the corrosion resistant tin andzinc metal alloy includes 30-65% tin; 35-70% zinc; 0-0.1% aluminum; 0-1%antimony and/or bismuth; 0-0.05% arsenic; 0-0.01% cadmium; 0-0.5%copper; 0-0.05% iron; 0-0.1% lead; 0-0.1% magnesium; 0-0.1% manganese;0-0.5% nickel; 0-0.05% silver; 0-0.05% titanium; and the tin plus zinccontent is at least 98% of the metal alloy. Still yet a furtherformulation of the corrosion resistant tin and zinc metal alloy includes40-60% tin; 40-60% zinc; 0-0.4% aluminum; 0-0.8% antimony and/orbismuth; 0-0.005% arsenic; 0-0.005% cadmium; 0-0.2% copper; 0-0.001%iron; 0.01-0.08% lead; 0-0.001% magnesium; 0-0.001% manganese; 0-0.05%nickel; 0-0.005% silver; 0-0.05% titanium; and the tin plus zinc contentis at least 99% of the metal alloy. Another formulation of the corrosionresistant tin and zinc metal alloy includes 15-90% tin; 10-85% zinc;0-5% aluminum; 0-7.5% antimony; 0-5% bismuth; 0-1% cadmium; 0-5% copper;0-5% nickel; and 0-0.5% titanium. Still another formulation of thecorrosion resistant tin and zinc metal alloy includes 20-80% tin; 20-80%zinc; 0-2% aluminum; 0-1% antimony; 0-0.05% arsenic; 0-1% bismuth;0-0.1% boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2%copper; 0-1% iron; 0-1% lead; 0-1% magnesium; 0-0.1% manganese; 0-0.1%molybdenum; 0-1% nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.05%tellurium; 0-0.5% titanium; and 0-0.1% vanadium. Yet another formulationof the corrosion resistant tin and zinc metal alloy includes 20-80% tin;20-80% zinc; 0-1% aluminum; 0-2% antimony; 0-0.02% arsenic; 0-1.5%bismuth; 0-0.5% boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium;0-2% copper; 0-1% iron; 0-1% lead; 0-0.4% magnesium; 0-0.1% manganese;0-0.1% molybdenum; 0-1% nickel; 0-0.05% silicon; 0-0.05% silver; 0-0.02%sulfur; 0-0.04% tellurium; 0-0.15% titanium; and 0-0.05% vanadium. Stillyet another formulation of the corrosion resistant tin and zinc metalalloy includes 30-70% tin; 30-70% zinc; 0-0.4% aluminum; 0-0.8%antimony; 0-0.005% arsenic; 0-0.5% bismuth; 0-0.1% boron; 0-0.05%cadmium; 0-0.1% carbon; 0-0.1% chromium; 0-1% copper; 0-0.6% iron;0-0.5% lead; 0-0.1% magnesium; 0-0.1% manganese; 0-0.05% molybdenum;0-0.7% nickel; 0-0.01% silicon; 0-0.01% silver; 0-0.01% sulfur; 0-0.01%tellurium; 0-0.1% titanium; 0-0.01% vanadium; and the tin plus zinccontent is at least 90 weight percent of the metal alloy. A furtherformulation of the corrosion resistant tin and zinc metal alloy includes40-60% tin; 40-60% zinc; 0-0.4% aluminum; 0-1% antimony and/or bismuth;0-0.001% arsenic; 0-0.01% boron; 0-0.005% cadmium; 0-0.05% carbon;0-0.05% chromium; 0-0.1% copper; 0-0.05% iron; 0-0.1% lead; 0-0.01%magnesium; 0-0.01% manganese; 0-0.01% molybdenum; 0-0.3% nickel;0-0.001% silicon; 0-0.001% silver; 0-0.001% sulfur; 0-0.001% tellurium;0-0.05% titanium; 0-0.001% vanadium; and the tin plus zinc content is atleast 95 weight percent of the metal alloy. Yet a further formulation ofthe corrosion resistant tin and zinc metal alloy includes 45-55% zinc;45-55% tin; 0-0.4% aluminum; 0-0.8% antimony and/or bismuth; 0-0.001%arsenic; 0-0.001% boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.05%copper; 0-0.001 iron; 0-0.08% lead; 0-0.001% magnesium; 0-0.001%manganese; 0-0.001% molybdenum; 0-0.1% nickel; 0-0.001% silicon;0-0.005% silver; 0-0.001% sulfur; 0-0.001% tellurium; 0-0.05% titanium;0-0.001% vanadium; and the tin content plus the zinc content is at least99% of the metal alloy. Another formulation of the corrosion resistanttin and zinc metal alloy includes 20-80% tin; 20-80% zinc; 0-1%aluminum; 0-2% antimony; 0-0.02% arsenic; 0-1.5% bismuth; 0-0.05% boron;0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2% copper; 0-1% iron;0-1% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1%nickel; 0-0.5% silicon; 0-0.05% silver; 0-0.02% sulfur; 0-0.04%tellurium; 0-0.15% titanium; and 0-0.05% vanadium. Yet anotherformulation of the corrosion resistant tin and zinc metal alloy includes30-70% tin; 30-70% zinc; 0-0.4% aluminum; 0-0.8% antimony; 0-0.005%arsenic; 0-0.5% bismuth; 0-0.1% boron; 0-0.05% cadmium; 0-0.1% carbon;0-0.1% chromium; 0-1% copper; 0-0.6% iron; 0-0.5% lead; 0-0.1%magnesium; 0-0.1% manganese; 0-0.05% molybdenum; 0-0.9% nickel; 0-0.01%silicon; 0-0.01% silver; 0-0.01% sulfur; 0-0.01% tellurium; 0-0.1%titanium; 0-0.01% vanadium; and the tin plus zinc content is at least 90weight percent of the metal alloy. Still another formulation of thecorrosion resistant tin and zinc metal alloy includes 40-60% tin; 40-60%zinc; 0-0.4% aluminum; 0-1% antimony and/or bismuth; 0-0.001% arsenic;0-0.01% boron; 0-0.005% cadmium; 0-0.05% carbon; 0-0.05% chromium;0-0.1% copper; 0-0.05% iron; 0-0.1% lead; 0-0.01% magnesium; 0-0.01%manganese; 0-0.01% molybdenum; 0-0.9% nickel; 0-0.001% silicon; 0-0.001%silver; 0-0.001% sulfur; 0-0.001% tellurium; 0-0.05% titanium; 0-0.001%vanadium; and the tin plus zinc content is at least 95 weight percent ofthe metal alloy. Still yet another formulation of the corrosionresistant tin and zinc metal alloy includes 45-55% zinc; 45-55% tin;0-0.4% aluminum; 0-0.8% antimony and/or bismuth; 0-0.001% arsenic;0-0.001% boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.05% copper;0-0.001% iron; 0-0.08% lead; 0-0.001% magnesium; 0-0.001% manganese;0-0.001% molybdenum; 0-0.9% nickel; 0-0.001% silicon; 0-0.005% silver;0-0.001% sulfur; 0-0.001% tellurium; 0-0.05% titanium; 0-0.001%vanadium; and the tin content plus the zinc content is at least 99% ofthe metal alloy. A further formulation of the corrosion resistant tinand zinc metal alloy includes 15-90% tin; 10-85% zinc; 0-0.5% aluminum;0-5.5% antimony; 0-1.7% bismuth; 0-2.7% copper; 0-0.4% magnesium; 0-1%nickel; 0-0.15% titanium. Yet a further formulation of the corrosionresistant tin and zinc metal alloy includes 15-90% tin; 10-85% zinc;0-0.3% aluminum; 0-1% antimony; 0-1.7% bismuth; 0-1% copper; 0-0.4%magnesium; 0-1% nickel; 0-0.15% titanium. Still a further formulation ofthe corrosion resistant tin and zinc metal alloy includes 15-80% tin;20-85% zinc; 0-0.3% aluminum; 0-1% antimony; 0-1.7% bismuth; 0-1%copper, 0-0.4% magnesium; 0-1% nickel; 0-0.15% titanium. Still yetfurther formulation of the corrosion resistant tin and zinc metal alloyincludes 15-80% tin; 20-85% zinc; 0-0.5% aluminum; 0-5.5% antimony;0-1.7% bismuth; 0-2.7% copper; 0-0.4% magnesium; 0-1% nickel; and0-0.15% titanium. Another formulation of the corrosion resistant tin andzinc metal alloy includes 15-70% tin; 30-85% zinc; 0-0.25% aluminum;0-1.5% copper; 0-0.02% chromium; 0-0.01% iron; 0-0.01% lead; 0-0.01%manganese; and 0-0.18% titanium. Still another formulation of thecorrosion resistant tin and zinc metal alloy includes 49.75-50.25% tin;49.75-50.25% zinc; 0-0.02% aluminum; 0-0.2% antimony; 0-0.2% arsenic;0-0.2% copper; 0-0.025% iron; 0-0.002% palladium; and 0-0.015% titanium.Yet another formulation of the corrosion resistant tin and zinc metalalloy includes 49.5-50.5% tin; 49.5-50.5% zinc; 0.005-0.21% aluminum;0.05-0.64% antimony; 0-0.001% arsenic; 0-0.004% bismuth; 0-0.001%cadmium; 0.01-0.3% copper; 0-0.001% iron; 0-0.001% nickel; 0-0.001%silver; 0.001-0.02% titanium. Still yet another formulation of thecorrosion resistant tin and zinc metal alloy includes 49.75-50.25% tin;49.75-50.25% zinc; 0-0.25% aluminum; 0-0.35% antimony; 0-0.02% arsenic;0-0.001% cadmium; 0-0.02% copper; 0-0.025% iron; 0-0.08% lead; and0-0.0175% titanium. A further formulation of the corrosion resistant tinand zinc metal alloy includes 35-70% tin; 30-65% zinc; 0-5% copper; and0-5% nickel. Yet a further formulation of the corrosion resistant tinand zinc metal alloy includes 20-80% tin; 20-85% zinc; 0-0.1% lead.Still a further formulation of the corrosion resistant tin and zincmetal alloy includes 15-30% tin; 70-85% zinc; and 0-0.1% lead. Yet afurther formulation of the corrosion resistant tin and zinc metal alloyincludes 15-90% tin; 10-85% zinc; and 0-2% magnesium. Still yet afurther formulation of the corrosion resistant tin and zinc metal alloyincludes 10-75% tin; 25-90% zinc; 0-0.25% aluminum; 0-1.5% copper;0-0.02% chromium; 0-0.01% iron; 0-0.01% lead; 0-0.01% manganese; and0-0.18% titanium. Another formulation of the corrosion resistant tin andzinc metal alloy includes 15-35% tin; 65-85% zinc; 0-7.5% antimony;0-1.7% bismuth; 0-0.1% iron; and 0-0.05% lead. Yet another formulationof the corrosion resistant tin and zinc metal alloy includes 15-70% tin;30-85% zinc; 0-7.5% antimony; 0-1.7% bismuth; 0-5% copper; 0-0.1% iron;0-0.05% lead; and 0.3-5% nickel. Still another formulation of thecorrosion resistant tin and zinc metal alloy includes 15-70% tin; 30-85%zinc; 0-7.5% antimony; 0-1.7% bismuth; 0-2% copper; 0-0.1% iron; 0-0.05%lead; and 0.3-1% nickel. Still yet another formulation of the corrosionresistant tin and zinc metal alloy includes 15-70% tin; 30-85% zinc;0.1-5% copper; and 0.3-5% nickel. A further formulation of the corrosionresistant tin and zinc metal alloy includes 35-70% tin; 30-65% zinc;0.1-2% copper; and 0.3-1% nickel. Still a further formulation of thecorrosion resistant tin and zinc metal alloy includes 35-70% tin; 30-65%zinc; 0.1-1.5% copper; and 0.3-0.9% nickel. A further formulation of thecorrosion resistant tin and zinc metal alloy includes at least 15% tin;zinc; and at least 0.05% antimony, bismuth and/or copper. Still afurther formulation of the corrosion resistant tin and zinc metal alloyincludes 10-20% zinc; 0-2.5% antimony; 0-0.5% bismuth; and the remaindertin. Still a further formulation of the corrosion resistant tin and zincmetal alloy includes 80-90% tin; 10-20% zinc; 0.5-1.7% bismuth; 0-2%copper; 0-0.1% iron; and 0-0.05% lead. Still yet a further formulationof the corrosion resistant tin and zinc metal alloy includes 80-90% tin;10-20% zinc; 0.5-7.5% antimony; 0-2% copper; 0-0.1% iron; and 0-0.05%lead. Another formulation of the corrosion resistant tin and zinc metalalloy includes 80-90% tin; 10-20% zinc; 0-0.5% antimony; 0-2% copper;0-0.1% iron; and 0-0.05% lead. Still another formulation of thecorrosion resistant tin and zinc metal alloy includes 80-90% tin; 10-20%zinc; 0-0.5% bismuth; 0-2% copper; 0-0.1% iron; and 0-0.05% lead. Yetanother formulation of the corrosion resistant tin and zinc metal alloyincludes 70-90% tin; 10-30% zinc; at least 0.01% antimony. Still yetanother formulation of the corrosion resistant tin and zinc metal alloyincludes 70-90% tin; 10-30% zinc; 0.01-1.7% bismuth. Still anotherformulation of the corrosion resistant tin and zinc metal alloy includes70-90% tin; 10-30% zinc; 0.1-2% iron. Yet another formulation of thecorrosion resistant tin and zinc metal alloy includes 70-90% tin; 10-30%zinc; 0.1-2% copper. Still yet another formulation of the corrosionresistant tin and zinc metal alloy includes a majority of tin and zinc,0-0.5% aluminum; 0-5.5% antimony; 0-2.7% copper; and 0-0.15% titanium. Afurther formulation of the corrosion resistant tin and zinc metal alloyincludes a majority of tin and zinc, 0-0.3% aluminum; 0-1% antimony; and0-1% copper. Yet a further formulation of the corrosion resistant tinand zinc metal alloy includes 20-90% tin; 10-80% zinc; 0-1% aluminum;0-5.5% antimony; 0-1.7% bismuth; 0-2.7% copper; 0-0.1% iron; 0-0.05%lead; 0-1% magnesium; 0-1% nickel; and 0-0.5% titanium. Still a furtherformulation of the corrosion resistant tin and zinc metal alloy includes20-80% tin; 20-80% zinc; 0-5% aluminum; 0-5.5% antimony; 0-1.5% bismuth;0-5% copper; 0-5% magnesium; 0-5% nickel; and 0-1% titanium. Still yet afurther formulation of the corrosion resistant tin and zinc metal alloyincludes 20-80% tin; 20-80% zinc; 0-0.5% aluminum; 0-5.5% antimony;0-1.7% bismuth; 0-2.7% copper; 0-0.4% magnesium; 0-1% nickel; and0-0.15% titanium. Still a further formulation of the corrosion resistanttin and zinc metal alloy includes 20-80% tin; 20-80% zinc; 0-0.3%aluminum; 0-1% antimony; 0-1.7% bismuth; 0-1% copper; 0-0.4% magnesium;0-0.7% nickel; and 0-0.15% titanium. Another formulation of thecorrosion resistant tin and zinc metal alloy includes a majority of tinand zinc, 0-0.5% aluminum; 0-2% antimony; 0-2% copper; and 0-0.15%titanium. Still another formulation of the corrosion resistant tin andzinc metal alloy includes a majority of tin and zinc, 0-0.3% aluminum;0-1% antimony; and 0-1% copper. Yet another formulation of the corrosionresistant tin and zinc metal alloy includes 20-90% tin; 10-80% zinc;0-2% aluminum; 0-2% antimony and/or bismuth; 0-2% copper; 0-1% iron;0-0.5% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-1% nickel; and0-0.15% titanium. Still yet another formulation of the corrosionresistant tin and zinc metal alloy includes 20-65% tin; 35-80% zinc;0-2% aluminum; 0-1% antimony and/or bismuth; 0-1% copper; 0-0.6% iron;0-0.5% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.7% nickel; and0-0.15% titanium. Yet another formulation of the corrosion resistant tinand zinc metal alloy includes 20-50% tin; 50-80% zinc; 0-0.3% aluminum;0.005-0.5% antimony and/or bismuth; 0-0.2% copper; 0-0.6% iron; 0-0.4%lead; 0-0.4% magnesium; 0-0.05% manganese; 0-0.1% nickel; and 0-0.15%titanium. A further formulation of the corrosion resistant tin and zincmetal alloy includes 15-90% tin; 10-85% zinc; 0-2% aluminum; 0-2%antimony; 0-1.7% bismuth; 0-2% copper; 0-1% iron; 0-1% lead; 0-2%magnesium; 0-2% nickel; and 0-1% titanium. Still a further formulationof the corrosion resistant tin and zinc metal alloy includes 30-85% tin;15-70% zinc; 0-1% aluminum; 0-1% antimony; 0-0.01% arsenic; 0-1%bismuth; 0-0.1% cadmium; 0-0.1% chromium; 0-1% copper; 0-0.1% iron;0-0.1% lead; 0-0.01% manganese; 0-0.1% nickel; 0-0.01% silver; and0-0.05% titanium. Still yet a further formulation of the corrosionresistant tin and zinc metal alloy includes 50-85% tin; 15-50% zinc;0-7.5% aluminum; 0-2% antimony; 0-0.05% arsenic; 0-0.1% boron; 0-1.7%bismuth; 0-0.5% cadmium; 0-1% carbon; 0-1% chromium; 0-5% copper; 0-1%iron; 0-10% lead; 0-1% magnesium; 0-0.1% manganese; 0-0.1% molybdenum;0-5% nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.05% tellurium; 0-0.5%titanium; and 0-0.1% vanadium. Yet a further formulation of thecorrosion resistant tin and zinc metal alloy includes 15-50% tin; 50-85%zinc; 0-7.5% aluminum; 0-2% antimony; 0-0.05% arsenic; 0-0.1% boron;0-1.7% bismuth; 0-0.5% cadmium; 0-1% carbon; 0-1% chromium; 0-5% copper;0-1% iron; 0-10% lead; 0-1% magnesium; 0-0.1% manganese; 0-0.1%molybdenum; 0-5% nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.05%tellurium; 0-0.5% titanium; and 0-0.1% vanadium. Still a furtherformulation of the corrosion resistant tin and zinc metal alloy includes20-80% tin; 20-80% zinc; 0-5% aluminum; 0-7.5% antimony; 0-5% bismuth;0-1% cadmium; 0-5% copper; 0-5% nickel; and 0-0.5% titanium. Still yet afurther formulation of the corrosion resistant tin and zinc metal alloyincludes 15-90% tin; 10-85% zinc; 0-7.5% aluminum; 0-2% antimony;0-0.05% arsenic; 0-0.1% boron; 0-1.7% bismuth; 0-0.5% cadmium; 0-1%carbon; 0-1% chromium; 0-5% copper; 0-1% iron; 0-10% lead; 0-1%magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-5% nickel; 0-0.5%silicon; 0-0.1% silver; 0-0.05% tellurium; 0-0.5% titanium; and 0-0.1%vanadium. Another formulation of the corrosion resistant tin and zincmetal alloy includes 30-70% tin; 30-70% zinc; 0-7.5% aluminum; 0-2%antimony; 0-1.7% bismuth; 0-0.5% cadmium; 0-5% copper; 0-10% lead; and0-5% nickel. Still another formulation of the corrosion resistant tinand zinc metal alloy includes 40-60% tin; 40-60% zinc; 0-2% aluminum;0-2% antimony, bismuth, cadmium and/or copper; 0-2% lead; and 0-1%nickel.

[0218] The following are several examples of tin or tin and zinc metalalloy being applied by various processes to various types of metalstrip. The following examples also illustrate various ways the coatedmetal strip can be formed in various types of products. The followingexamples further illustrate the formation of the metal alloy into variustypes of materials. The following examples only illustrate a few, notall, aspects of the present invention.

EXAMPLE A

[0219] A metal strip is unwound from a roll of metal strip. The metalstrip has a thickness of less than about 762 microns. The metal strip iscontinuously passed through an electrolytic tank to plate nickel on thestrip surface. The nickel plated layer has a thickness of about 1-3microns. The metal alloy includes at least about 85% tin and at leastabout 10% zinc and less than about 0.5% lead. The metal alloy in themelting pot at a temperature of about 301-455° C. The metal strip ispassed through the melting pot having a length of about 16 feet at aspeed of about 100 ft/min. The metal strip has a resident time in themelting pot of less than about 10 seconds. The coated metal strip ispassed through coating rollers and/or an air-knife to achieve a coatingthickness of about 7-77 microns. The coated metal strip is rewound intoa roll of coated metal strip.

EXAMPLE B

[0220] A metal strip is unwound from a roll of metal strip. The metalstrip has a thickness of less than about 762 microns. The metal strip isplated with chromium of a thickness of less than about 3 microns. Ametal alloy having a composition of at least about 45% tin, at leastabout 45% zinc, less than about 1% of a metal additive, and less thanabout 0. 1% lead is coated onto the metal strip. The metal alloy isheated in a melting pot at a temperature of about 301-482° C. The stripis passed through the melting pot having a length of about 16 feet at aspeed of about 100 ft/min. The metal strip has a resident time in themelting pot of less than about 10 seconds. The coated metal strip ispassed through coating rollers and/or an air-knife to achieve a coatingthickness of about 7-77 microns. The coated metal strip is rewound intoa roll of coated metal strip.

EXAMPLE C

[0221] A metal strip is unwound from a roll of metal strip. The metalstrip has a thickness of less than about 762 microns. The metal strip iscontinuously plated with a tin layer of about 1-3 microns thick. A metalalloy having a composition of at least about 45% tin and at least about45% zinc is coated onto the metal strip. The metal alloy is heated in amelting pot at a temperature of about 301-482° C. The metal strip ispassed through the melting pot having a length of about 16 feet at aspeed of about 100 ft./min. The metal strip has a resident time in themelting pot of less than about 10 seconds. The coated metal strip ispassed through coating rollers and/or an air-knife to achieve a coatingthickness of about 7-77 microns. The coated metal strip is rewound intoa roll of coated metal strip.

EXAMPLE D

[0222] A metal strip is unwound from a roll of metal strip andcontinuously plated with a tin layer of a thickness of less than about 3microns. The metal strip has a thickness of less than about 762 microns.A metal alloy having a composition of at least about 45% tin, at leastabout 45% zinc, and less than about 0. 1% lead is coated onto the metalstrip. The metal alloy is heated in a melting pot at a temperature ofabout 301-427° C. The metal strip is passed through the melting pothaving a length of about 16 feet at a speed of about 100 ft/min. Themetal strip has a resident time in the melting pot of less than about 10seconds. The coated metal strip is passed through coating rollers and/oran air-knife to achieve a coating thickness of about 7-77 microns. Thecoated metal strip is rewound into a roll of coated metal strip.

EXAMPLE E

[0223] A metal strip is unwound from a roll of metal strip. The metalstrip is continuously plated with a tin layer of about 1-3 micronsthick. The metal strip has a thickness of less than about 762 microns. Ametal alloy having a composition of at least about 20% tin, and at leastabout 75% zinc and is heated in a melting pot at a temperature of about301-427° C. The metal strip is passed through the melting pot having alength of about 16 feet at a speed of about 100 ft/min. The metal striphas a resident time in the melting pot of less than about 10 seconds.The coated metal strip is passed through coating rollers and/or anair-knife to achieve a coating thickness of about 7-77 microns. Thecoated metal strip is rewound into a roll of coated metal strip.

EXAMPLE F

[0224] A metal strip is unwound from a roll of metal strip and ispickled with a hydrochloric acid solution and a copper sulfate solution.Copper is plated onto the metal strip surface during the picklingprocess forming a copper layer of about 1-3 microns thick. The metalstrip has a thickness of less than about 762 microns. The metal alloyincludes at least about 70% tin, at least about 25% zinc, and less thanabout 0.2% lead. The metal alloy in the melting pot is heated to atemperature of about 301-482° C. The metal strip is passed through themelting pot having a length of about 16 feet at a speed of about 100f/min. The metal strip has a resident time in the melting pot of lessthan about 10 seconds. The coated metal strip is passed through coatingrollers and/or an air-knife to achieve a coating thickness of about 7-77microns. The coated metal strip is rewound into a roll of coated metalstrip.

EXAMPLE G

[0225] A metal strip is unwound from a roll of metal strip and ispickled with a hydrochloric acid solution and chemically activated witha zinc chloride solution prior to coating the metal alloy. The metalstrip has a thickness of less than about 762 microns. The metal strip isnot pre-heated prior to coating. A tin metal alloy having a compositionof about 90-99% tin and less than about 2% lead is coated onto the metalstrip. The tin metal alloy in the melting pot is heated to at leastabove 238-246° C. The metal strip is passed through the melting pot at aspeed of about 100 ft/min. The metal strip has a resident time in themelting pot of less than about 10 seconds. The coated metal strip ispassed through coating rollers and/or an air knife to achieve a coatingthickness of about 7-51 microns. The coated metal strip is then cooled.The coated metal strip is then oxidized to remove the coated tin metalalloy and to expose and passify the heat created intermetallic layer.The metal strip is then wound into a roll of the metal strip.

EXAMPLE H

[0226] A metal strip is unwound from a roll of metal strip and ispickled with a hydrochloric acid solution and chemically activated witha zinc chloride solution prior to coating. The metal strip has athickness of less than about 762 microns. The metal strip is plated withnickel having a thickness of less than about 3 microns. The metal stripis preheated prior to coating. A tin metal alloy having a composition ofabove 90-99% tin and less than about 2% lead is coated onto the metalstrip. The metal alloy is heated in a melting pot to a temperature ofabout 238-482° C. The metal strip is passed through the melting pot at aspeed of about 100 ft/min. The metal strip has a resident time in themelting pot of less than about 10 seconds. The coated metal strip ispassed through coating rollers and/or an air-knife to achieve a coatingthickness of about 7-51 microns. The coated metal strip is cooled andthen oxidized to remove the tin metal alloy to expose and passify theheat created intermetallic layer. The metal strip is then wound into aroll of metal strip.

EXAMPLE I

[0227] A metal strip is unwound from a roll of metal strip. The metalstrip has a thickness of less than about 762 microns. The metal strip isnot pre-heated prior to coating with a metal alloy. A tin metal alloyhaving a composition of about 90-99% tin, and less than about 0-5% leadis coated onto the metal strip. The tin metal alloy is applied to themetal strip by an electroplating process. The plated metal strip is thenflow heated for less than about 5 minutes. The coated metal strip isthen passed through coating rollers and/or an air-knife to achieve acoating thickness of about 7-51 microns. The coated metal strip is thencooled. The coated metal strip is then oxidized to remove the tin metalalloy and to expose and passify the heat created intermetallic layer.The metal strip is then wound into a roll of metal strip.

EXAMPLE J

[0228] A metal strip is unwound from a roll of metal strip and platedwith a zinc layer having a thickness of less than about 3 microns. Themetal strip has a thickness of less than about 762 microns. The metalstrip is pre-heated prior to coating with a metal alloy. A tin metalalloy having a composition of about 90-99% tin and less than about 0-1%lead is coated onto the metal strip. The metal strip is passed through ametal spaying process at a speed of up to about 100 ft/min to coat themetal strip. The coated metal strip is then passed through coatingrollers and/or an air-knife to achieve a coating thickness of about 7-51microns. The coated metal strip is cooled and then oxidized to removethe tin metal alloy and to expose and passify the heat createdintermetallic layer. The metal strip is then cut into metal sheets.

EXAMPLE K

[0229] A metal strip is unwound from a roll of metal strip and ispickled with an acid solution and then chemically activated with achemical activation solution. The metal strip is then plated with ametal layer of about 1-3 microns thick. The metal strip is notpre-heated prior to coating with a metal alloy. A tin metal alloy havinga composition of about 90-99% tin is coated onto the metal strip. Thetin metal alloy is plated onto the metal strip and then flow heated. Themetal strip is then coated again by a spray metal process. The coatedmetal strip is then passed through coating rollers and/or an air-knifeto achieve a coating thickness of about 7-51 microns. The coated metalstrip is then cooled and wound into a roll of coated metal strip. Theroll of coated metal strip is formed into roofing materials andinstalled on a building. The formed coated metal strip is then exposedto an oxidizing solution on site to remove the tin metal alloy andexpose and passify the heat created intermetallic layer.

EXAMPLE L

[0230] A carbon steel strip is unwound from a roll of carbon steelstrip. The carbon steel strip has a thickness of less than about 762microns. The carbon steel strip is continuously passed through anelectrolytic tank to plate nickel on the carbon steel strip surface. Thenickel plated layer has a thickness of about 1-3 microns. A metal alloyhaving a composition of at least about 95% tin and zinc, and less thanabout 0.5% lead is coated onto the carbon steel strip. The metal alloyin the melting pot is at a temperature of about 301-455° C. The carbonsteel strip is passed through the melting pot having a length of about16 feet at a speed of about 100 ft/min. The carbon steel strip has aresident time in the melting pot of less than about 10 seconds. Thecoated carbon steel strip is passed through coating rollers and/or anair-knife to achieve a coating thickness of about 7-77 microns. Thecoated carbon steel strip is rewound into a roll of coated carbon steelstrip.

EXAMPLE M

[0231] A carbon steel strip is unwound from a roll of carbon steelstrip. The carbon steel strip has a thickness of less than about 762microns. The carbon steel strip is plated with chromium of a thicknessof less than about 3 microns. A metal alloy having a composition of atleast about 98% tin and zinc, less than about 1% of a metal additive,less than about 0.1% lead is coated onto the carbon steel strip. Themetal alloy is heated in a melting pot at a temperature of about301-482° C. The carbon steel strip is passed through the melting pothaving a length of about 16 feet at a speed of about 100 ft/min. Thecarbon steel strip has a resident time in the melting pot of less thanabout 10 seconds. The coated carbon steel strip is passed throughcoating rollers and/or an air-knife to achieve a coating thickness ofabout 7-77 microns. The coated carbon steel strip is rewound into a rollof coated carbon steel strip.

EXAMPLE N

[0232] A copper strip is unwound from a roll of copper strip. The copperstrip has a thickness of less than about 762 microns. The copper stripis continuously plated with a tin layer of about 1-3 microns thick. Ametal alloy having a composition of at least about 99% tin and zinc iscoated onto the copper strip. The metal alloy is heated in a melting potat a temperature of about 301-482° C. The coated strip is passed throughthe melting pot having a length of about 16 feet at a speed of about 100ft./min. The copper strip has a resident time in the melting pot of lessthan about 10 seconds. The coated copper strip is passed through coatingrollers and/or an air-knife to achieve a coating thickness of about 7-77microns. The coated copper strip is rewound into a roll of coated copperstrip.

EXAMPLE O

[0233] A carbon steel strip is unwound from a roll of carbon steel stripand continuously plated with a tin layer of a thickness of less thanabout 3 microns. The carbon steel strip has a thickness of less thanabout 762 microns. A metal alloy having a composition of at least about98% tin and zinc, and less than about 0.1% lead is coated onto thecarbon steel strip. The metal alloy is heated in a melting pot at atemperature of about 301-427° C. The carbon steel strip is passedthrough the melting pot having a length of about 16 feet at a speed ofabout 100 ft/min. The carbon steel strip has a resident time in themelting pot of less than about 10 seconds. The coated carbon steel stripis passed through coating rollers and/or an air-knife to achieve acoating thickness of about 7-77 microns. The coated carbon steel stripis rewound into a roll of coated carbon steel strip.

EXAMPLE P

[0234] A stainless steel strip is unwound from a roll of stainless steelstrip. The stainless steel strip is continuously plated with a tin layerof about 1-3 microns thick. The stainless steel strip has a thickness ofless than about 762 microns. A metal alloy having a composition of atleast about 98-99% tin and zinc is heated in a melting pot at atemperature of about 301-427° C. The stainless steel strip is passedthrough the melting pot having a length of about 16 feet at a speed ofabout 100 ft/min. The stainless steel strip has a resident time in themelting pot of less than about 10 seconds. The coated stainless steelstrip is passed through coating rollers and/or an air-knife to achieve acoating thickness of about 7-77 microns. The coated stainless steelstrip is rewound into a roll of coated stainless steel strip.

EXAMPLE Q

[0235] A carbon steel strip is unwound from a roll of carbon steel stripand is pickled with a hydrochloric acid solution and a copper sulfatesolution. Copper is plated onto the carbon steel strip surface duringthe pickling process to form a copper layer of about 1-3 microns thick.The carbon steel strip has a thickness of less than about 762 microns. Ametal alloy having a composition of at least about 95-99% tin and zinc,and less than about 0.2% lead is coated onto the carbon steel strip. Themetal in a melting pot is heated to a temperature of about 301-482° C.The carbon steel strip is passed through the melting pot having a lengthof about 16 feet at a speed of about 100 ft/min. The carbon steel striphas a resident time in the melting pot of less than about 10 seconds.The coated carbon steel strip is passed through coating rollers and/oran air-knife to achieve a coating thickness of about 7-77 microns. Thecoated carbon steel strip is rewound into a roll of coated carbon steelstrip.

EXAMPLE R

[0236] A carbon steel strip is unwound from a roll of carbon steel stripand is pickled with a hydrochloric acid solution and chemicallyactivated with a zinc chloride solution prior to coating. The carbonsteel strip has a thickness of less than about 762 microns. The carbonsteel strip is not pre-heated prior to coating. A metal alloy having acomposition of about 90-95% tin, and less than about 0.5% lead is coatedonto the carbon steel strip. The metal alloy in the melting pot isheated to a temperature of about 238-246° C. The melting pot is heatedby four external gas torches directed to the outer sides of the meltingpot. The carbon steel strip is passed through the melting pot having alength of about 16 feet at a speed of about 100 ft/min. The carbon steelstrip has a resident time in the melting pot of less than about 10seconds. The coated carbon steel is passed through coating rollersand/or an air-knife to achieve a coating thickness of about 7-51microns. The coated carbon steel strip is then cooled and rewound into aroll of coated carbon steel strip.

EXAMPLE S

[0237] A carbon steel strip is unwound from a roll of carbon steel stripand is pickled with a hydrochloric acid solution and chemicallyactivated with a zinc chloride solution prior to coating. The carbonsteel strip has a thickness of less than about 762 microns. The carbonsteel strip is plated with chromium of a thickness of less than about 3microns: The carbon steel strip is not pre-heated prior to coating. Ametal alloy having a composition of about 90-99% tin, about 0.01-1%metallic stabilizer selected from antimony, bismuth and/or copper, andless than about 0.5% lead is coated onto the carbon steel strip. Themetal alloy is heated in a melting pot at a temperature of about238-482° C. The melting pot is heated by four external gas torchesdirected to the outer sides of the melting pot. The carbon steel stripis passed through the melting pot having a length of about 16 feet at aspeed of about 100 ft/min. The carbon steel strip has a resident time inthe melting pot of less than about 10 seconds. The coated carbon steelstrip is passed through coating rollers and/or an air-knife to achieve acoating thickness of about 7-51 microns. The coated carbon steel stripis then cooled and rewound into a roll of coated carbon steel strip.

EXAMPLE T

[0238] A copper strip is unwound from a roll of copper strip and ispickled with a hydrochloric acid solution and chemically activated witha zinc chloride solution prior to coating. The copper strip has athickness of less than about 762 microns. The copper strip is notpre-heated prior to coating. A metal alloy having a composition of about90-99% tin, 0-1% metallic stabilizer, and less than about 0. 1% lead iscoated onto the copper strip. The metal alloy is heated in a melting potat a temperature of about 238-246° C. The melting pot is heated by fourexternal gas torches directed to the outer sides of the melting pot. Thecopper strip is passed through the melting pot having a length of about16 feet at a speed of about 100 ft./min. The copper strip has a residenttime in the melting pot of less than about 10 seconds. The coated copperstrip is passed through coating rollers and/or an air-knife to achieve acoating thickness of about 7-51 microns. The coated copper strip is thencooled and rewound into a roll of coated copper strip.

EXAMPLE U

[0239] A carbon steel strip is unwound from a roll of carbon steel stripand plated with a nickel layer of a thickness of less than about 3microns. The carbon steel strip has a thickness of less than about 762microns. The carbon steel strip is not pre-heated prior to coating. Ametal alloy having a composition of about 90-99% tin, and less thanabout 0.1% lead is coated onto the carbon steel strip. The metal alloyis heated in a melting pot at a temperature of about 238-255° C. Themelting pot is heated by four external gas torches directed to the outersides of the melting pot. The carbon steel strip is passed through thecoating tank having a length of about 16 feet at a speed of about 100ft/min. The carbon steel strip has a resident time in the melting pot ofless than about 10 seconds. The coated carbon steel strip is passedthrough coating rollers and/or an air-knife to achieve a coatingthickness of 7-51 microns. The coated carbon steel strip is then cooledand rewound into a roll of coated carbon steel strip.

EXAMPLE V

[0240] A stainless steel strip is unwound from a roll of stainless steelstrip and is aggressively pickled with a dual acid solution ofhydrochloric acid and nitric acid and chemically activated with a zincchloride solution. The stainless steel strip is plated with a nickellayer of about 1-3 microns thick. The stainless steel strip has athickness of less than about 762 microns. The stainless steel strip isnot pre-heated prior to coating. A metal alloy having a composition ofabout 90-99% tin and is heated in a melting pot at a temperature ofabout 238-260° C. The melting pot is heated by four external gas torchesdirected to the outer sides of the melting pot. The stainless steelstrip is passed through the melting pot having a length of about 16 feetat a speed of about 100 ft/min. The stainless steel strip has a residenttime in the melting pot of less than about 10 seconds. The coatedstainless steel strip is passed through coating rollers and/or anair-knife to achieve a coating thickness of about 7-51 microns. Thecoated stainless steel strip is then cooled and rewound into a roll ofcoated stainless steel strip.

EXAMPLE W

[0241] A carbon steel strip is unwound from a roll of carbon steel stripand is pickled with a hydrochloric acid solution and a copper sulfatesolution and chemically activated with a zinc chloride solution prior tocoating. Copper is plated onto the carbon steel strip surface during thepickling process to form a copper layer of about 1-3 microns thick. Thecarbon steel strip has a thickness of less than about 762 microns. Thecarbon steel strip is not pre-heated prior to coating. A metal alloyhaving a composition of about 90-95% tin and less than about 0.5% leadis coated onto the carbon steel strip. The metal alloy is heated in amelting pot at a temperature of about 238-250° C. The melting pot isheated by four external gas torches directed to the outer sides of themelting pot. The carbon steel strip is passed through the melting pothaving a length of about 16 feet at a speed of about 100 ft/min. Thecarbon steel strip has a resident time in the melting pot of less thanabout 10 seconds. The coated carbon steel strip is passed throughcoating rollers and/or an air-knife to achieve a coating thickness ofabout 7-51 microns. The coated carbon steel strip is then cooled andrewound into a roll of coated carbon steel strip.

EXAMPLE X

[0242] A carbon steel strip is unwound from a roll of carbon steel stripand is pickled with a hydrochloric acid solution and chemicallyactivated with a zinc chloride solution prior to coating. The carbonsteel strip has a thickness of more than about 762 microns. The carbonsteel strip is pre-heated prior to coating. A metal alloy having acomposition of about 90-99% tin and less than about 0.1% lead is coatedonto the carbon steel strip. The metal alloy is heated in a melting potat a temperature of about 237-246° C. The melting pot is heated by fourexternal gas torches directed to the outer sides of the melting pot. Thecarbon steel strip is passed through the melting pot having a length ofabout 16 feet at a speed of about 100 ft/min. The carbon steel strip hasa resident time in the melting pot of less than about 10 seconds. Thecoated carbon steel strip is passed through coating rollers and/or anair-knife to achieve a coating thickness of about 7-51 microns. Thecoated carbon steel strip is then cooled and rewound into a roll ofcoated carbon steel strip.

EXAMPLE Y

[0243] A thin strip of carbon steel uncoiled from a roll of carbon steelis passed through an electroplating bath to deposit an ultra thin layerof tin on the carbon steel strip. The carbon steel strip had a thicknessof less than about 762 microns. The carbon steel strip is then coatedwith a two-phase zinc-tin coating to produce an intermetallic layerbetween the metal alloy and the carbon steel strip. The tin-zinc metalalloy has a coating of tin and zinc content at least about 75 weightpercent.

EXAMPLE Z

[0244] The process of Example Y was performed with the addition of aheating furnace to flow heat the thin tin plating and, thus, form a heatcreated intermetallic layer including iron and tin prior to the metalalloy coating process.

EXAMPLE AA

[0245] The process of Example Y was performed with copper being platedon the carbon steel strip by an electrolytic bath.

EXAMPLE BB

[0246] A copper strip is unwound from a roll of copper strip. The copperstrip has a thickness of less than about 762 microns. The copper stripis pickled with an acid to clean the surface of the copper strip. Thecopper strip is continuously passed through an electrolytic tank toplate nickel on the copper strip surface. The nickel plated layer has athickness of about 1-3 microns. The copper strip is no preheated. Ametal alloy having a composition of at least about 95% tin and zinc, andless than about 0.5% lead is coated onto the copper strip. The metalalloy is in a melting pot at a temperature of about 301-454° C. Thecopper strip is passed through the melting pot having a length of about16 feet at a speed of about 100 ft/min. The copper strip has a residenttime in the melting pot of less than about 10 seconds. The coated copperstrip is passed through coating rollers and/or an air-knife to achieve acoating thickness of about 7-77 microns. The coated copper strip isrewound into a roll of coated copper strip.

EXAMPLE CC

[0247] A brass strip is unwound from a roll of brass strip. The brassstrip has a thickness of less than about 762 microns. The brass strip ispickled to remove surface oxides. The brass strip is plated withchromium having a thickness of less than about 3 microns. The brassstrip is not preheated. A metal alloy having a composition of at leastabout 98% tin and zinc, less than about 1% of a metal additive, and lessthan about 0.1% lead is coated onto the brass strip. The metal alloy isheated in a melting pot at a temperature of about 301-482° C. The brassstrip is passed through the melting pot having a length of about 16 feetat a speed of about 100 ft/min. The brass strip has a resident time inthe melting pot of less than about 10 seconds. The coated brass strip ispassed through coating rollers and/or an air-knife to achieve a coatingthickness of about 7-77 microns. The coated brass strip is rewound intoa roll of coated brass strip.

EXAMPLE DD

[0248] A bronze strip is unwound from a roll of bronze strip. The bronzestrip has a thickness of less than about 762 microns. The copper stripis continuously plated with a tin layer of about 1-3 microns thick. Ametal alloy having a composition of at least about 99% tin and zinc iscoated onto the bronze strip. The metal alloy is heated in a melting potat a temperature of about 301-482° C. The bronze strip is passed throughthe melting pot having a length of about 16 feet at a speed of about 100ft./min. The bronze strip has a resident time in the melting pot of lessthan about 10 seconds. The coated bronze strip is passed through coatingrollers and/or an air-knife to achieve a coating thickness of about 7-77microns. The coated bronze strip is rewound into a roll of coated bronzestrip.

EXAMPLE EE

[0249] A carbon steel strip is unwound from a roll of carbon steel stripand continuously plated with a tin layer of a thickness of less thanabout 3 microns. The carbon steel strip has a thickness of less than 762microns. A metal alloy having a composition of at least about 98% tinand zinc, and less than about 0.1% lead is coated onto the carbon steelstrip. The metal alloy is plated and subsequently flow heated onto thesurface of the carbon steel strip. The coated carbon steel strip ispassed through an air-knife to achieve a coating thickness of about 7-77microns. The coated carbon steel strip is oxidized to expose the heatcreated intermetallic layer. The oxidized carbon steel strip is rewoundinto a roll of oxidized carbon steel strip.

EXAMPLE FF

[0250] A stainless steel strip is unwound from a roll of stainless steelstrip. The stainless steel strip is aggressively pickled and chemicallyactivated to clean the stainless steel strip surface. The stainlesssteel strip is continuously plated with a tin layer of about 1-3 micronsthick. The stainless steel strip has a thickness of less than about 762microns. The stainless steel strip is preheated. A metal alloy having acomposition of at least about 98-99% tin and zinc is heated in a meltingpot at a temperature of about 301-427° C. The stainless steel strip ispassed through the melting pot having a length of about 16 feet at aspeed of about 100 ft/min. The stainless steel strip has a resident timein the melting pot of less than about 10 seconds. The coated stainlesssteel strip is passed through coating rollers and/or an air-knife toachieve a coating thickness of about 7-77 microns. The coated stainlesssteel strip is oxidized to expose the heat created intermetallic layer.The oxidized stainless steel strip is rewound into a roll of oxidizedstainless steel strip.

EXAMPLE GG

[0251] A carbon steel strip is unwound from a roll of carbon steel stripand is pickled with a hydrochloric acid solution and a copper sulfatesolution. Copper is plated onto the carbon steel strip surface duringpickling to form a copper layer of about 1-3 microns thick. The carbonsteel strip has a thickness of less than about 762 microns. A metalalloy having a composition of at least about 95-99% tin and zinc, andless than about 0.2% lead is coated onto the carbon steel strip. Themetal alloy is plated and subsequently flow heated onto the carbon steelstrip. The coated carbon steel strip is passed through coating rollersand/or an air-knife to achieve a coating thickness of about 7-77microns. The coated carbon steel strip is rewound into a roll of coatedcarbon steel strip.

EXAMPLE HH

[0252] A brass strip is unwound from a roll of brass strip. The brassstrip has a thickness of less than about 762 microns. The brass iscontinuously passed through an electrolytic tank to plate nickel on thebrass strip surface. The nickel plated layer has a thickness of about1-3 microns. A metal alloy having a composition of 95-98% tin and zinc,and less than about 0.5% lead is coated onto the brass strip. The metalalloy in a melting pot is heated to a temperature of about 301-455° C.The carbon steel strip is passed through the melting pot having a lengthof about 16 feet at a speed of about 100 ft/min. The brass strip has aresident time in the melting pot of less than about 10 seconds. Thecoated brass strip is passed through coating rollers and/or an air-knifeto achieve a coating thickness of about 7-77 microns. The coated brassstrip is rewound into a roll of coated brass strip.

EXAMPLE II

[0253] A tin strip is unwound from a roll of tin strip. The tin striphas a thickness of less than about 762 microns. The tin strip is platedwith chromium of a thickness of less than about 3 microns. A metal alloyhaving a composition of about 95-98% tin and zinc, less than about 2% ofa metal additive, and less than about 0.5% lead is coated onto the tinstrip. The metal alloy is heated in a melting pot at a temperature ofabout 301-482° C. The tin strip is passed through the melting pot havinga length of about 16 feet at a speed of about 100 ft/min. The tin striphas a resident time in the melting pot of less than about 10 seconds.The coated tin strip is passed through coating rollers and/or anair-knife to achieve a coating thickness of about 7-77 microns. Thecoated tin strip is rewound into a roll of coated tin strip.

EXAMPLE JJ

[0254] A copper strip is unwound from a roll of copper strip. The copperstrip has a thickness of less than about 762 microns. The copper stripis continuously plated with a tin layer of about 1-3 microns thick. Ametal alloy having a composition of about 90-99% tin and 0-5% lead iscoated onto the copper strip. The metal alloy is heated in a melting potat a temperature of about 301-482° C. The copper strip is passed throughthe melting pot having a length of about 16 feet at a speed of about 100ft./min. The copper strip has a resident time in the melting pot of lessthan about 10 seconds. The coated copper strip is passed through coatingrollers and/or an air-knife to achieve a coating thickness of about 7-77microns. The coated copper strip is rewound into a roll of coated copperstrip.

EXAMPLE KK

[0255] A carbon steel strip is unwound from a roll of carbon steel stripand continuously plated with a tin layer of a thickness of less thanabout 3 microns. The carbon steel strip has a thickness of less thanabout 762 microns. A metal alloy having a composition of about 90-99%tin and zinc, and less than about 0.5% lead is coated onto the carbonsteel strip. The metal alloy is heated in a melting pot at a temperatureof about 301-482° C. The carbon steel strip is passed through themelting pot having a length of about 16 feet at a speed of about 100ft/min. The carbon steel has a resident time in the melting pot of lessthan about 10 seconds. The coated carbon steel strip is passed throughcoating rollers and/or an air-knife to achieve a coating thickness ofabout 7-77 microns. The coated carbon steel strip is rewound into a rollof coated carbon steel strip.

EXAMPLE LL

[0256] A stainless steel strip is unwound from a roll of stainless steelstrip. The stainless steel strip is continuously plated with a tin layerof about 1-3 microns thick. The stainless steel strip has a thickness ofless than about 762 microns. A metal alloy having a composition of about90-99% tin and zinc is heated in a melting pot at a temperature of about301-482° C. The stainless steel strip is passed through the melting pothaving a length of about 16 feet at a speed of about 100 ft/min. Thestainless steel strip has a resident time in the melting pot of lessthan about 10 seconds. The coated stainless steel strip is passedthrough coating rollers and/or an air-knife to achieve a coatingthickness of about 7-77 microns. The coated stainless steel strip isrewound into a roll of coated stainless steel strip.

EXAMPLE MM

[0257] A brass strip is unwound from a roll of brass strip and ispickled with a hydrochloric acid solution and a copper sulfate solution.Copper is plated onto the carbon steel strip surface during pickling toform a copper layer of about 1-3 microns thick. The brass strip has athickness of less than about 762 microns. A metal alloy having acomposition of about 90-95% tin, and less than about 0.5% lead is heatedin a melting pot at a temperature of about 301-482° C. The brass stripis passed through the melting pot having a length of about 16 feet at aspeed of about 100 ft/min. The brass strip has a resident time in themelting pot of less than about 10 seconds. The coated brass strip ispassed through coating rollers and/or an air-knife to achieve a coatingthickness of about 7-77 microns. The coated brass strip is rewound intoa roll of coated brass strip.

EXAMPLE NN

[0258] A copper strip is unwound from a roll of copper strip and ispickled with a hydrochloric acid solution and chemically activated witha zinc chloride solution prior to coating. The copper strip has athickness of less than about 762 microns. The copper strip is notpre-heated prior to coating. A tin alloy having a composition of about90-99% tin, and less than about 2% lead is heated in a melting pot at atemperature of about 237-246° C. The copper strip is passed through themelting pot at a speed of about 100 ft/min. The copper strip has aresident time in the coating tank of less than about 10 seconds. Thecoated copper strip is passed through coating rollers and/or an airknife to achieve a coating thickness of about 7-51 microns. The coatedcopper strip is then cooled. The coated copper strip is then oxidized toremove the coated tin alloy and to expose and pacify the heat createdintermetallic layer. The copper strip is then wound into a roll ofcopper strip.

EXAMPLE OO

[0259] A copper strip is unwound from a roll of copper strip and ispickled with a hydrochloric acid solution and chemically activated witha zinc chloride solution prior to coating. The copper strip has athickness of less than about 762 microns. The copper strip is platedwith nickel having a thickness of less than about 3 microns. The copperstrip is preheated prior to coating. A tin alloy having a composition ofabout 90-99% tin, and less than about 2% lead is heated in a melting potat a temperature of about 237-482° C. The copper strip is passed throughthe melting pot at a speed of about 100 ft/min. The copper strip has aresident time in the melting pot of less than about 10 seconds. Thecoated copper strip is passed through coating rollers and/or anair-knife to achieve a coating thickness of 7-51 microns. The coatedcopper strip is cooled and then oxidized to remove the tin alloy and toexpose and pacify the heat created intermetallic layer. The copper stripis then wound into a roll of copper strip.

EXAMPLE PP

[0260] A copper strip is unwound from a roll of copper strip. The copperstrip has a thickness of less than about 762 microns. The strip is notpre-heated prior to coating. A tin alloy having a composition of about99% tin, and less than about 0-5% lead is applied to the copper strip byan electroplating process. The plated copper strip is then flow heatedfor less than about 5 minutes. The coated copper strip is passed throughcoating rollers and/or an air-knife to achieve a coating thickness ofabout 7-51 microns. The coated copper strip is then cooled. The coatedcopper strip is then oxidized to remove the tin alloy and to expose andpacify the heat created intermetallic layer. The copper strip is thenwound into a roll of copper strip.

EXAMPLE QQ

[0261] A copper steel strip is unwound from a roll of copper strip andplated with a chromium layer having a thickness of less than about 3microns. The copper strip has a thickness of less than about 762microns. The copper strip is pre-heated prior to coating. A tin alloyhaving a composition of about 90-99% tin, and less than about 0-1% leadis coated onto the copper strip. The copper strip is passed through ametal spaying process at a speed of up to about 100 ft/min. The coatedcopper strip is then passed through coating rollers and/or an air-knifeto achieve a coating thickness of about 7-51 microns. The coated copperstrip is cooled and then oxidized to remove the tin alloy to expose andpacify the heat created intermetallic layer. The copper strip is thencut into sheets.

EXAMPLE RR

[0262] A copper strip is unwound from a roll of copper strip and ispickled with an acid solution and then chemically activated with achemical activation solution. The copper strip is plated with a metallayer of about 1-3 microns thick. The copper strip is not pre-heatedprior to coating. A tin alloy having a composition of about 90-99% tinis metal sprayed onto the copper strip. The coated copper strip is thenpassed through coating rollers and/or an air-knife to achieve a coatingthickness of about 7-51 microns. The coated copper strip is then cooledand wound into a roll of copper strip. The roll of coated copper stripis later formed into roofing materials and installed on a building. Theformed coated copper strip is then exposed on site to an oxidizingsolution to remove the tin alloy and expose and pacify the intermetalliclayer.

EXAMPLE SS

[0263] A tin strip is unwound from a roll of tin strip. The tin striphas a thickness of less than about 762 microns. The tin strip iscontinuously passed through an electrolytic tank to plate nickel on thetin strip surface. The nickel plated layer has a thickness of about 1-3microns. A metal alloy having a composition of at least about 85% tin,at least about 10% zinc, and less than about 0.5% lead is heated in amelting pot at a temperature of about 301-455° C. The tin strip ispassed through the melting pot having a length of about 16 feet at aspeed of about 100 ft/min. The tin strip has a resident time in themelting pot of less than about 10 seconds. The coated tin strip ispassed through coating rollers and/or an air-knife to achieve a coatingthickness of about 7-77 microns. The coated tin strip is rewound into aroll of coated tin strip.

EXAMPLE TT

[0264] A bronze strip is unwound from a roll of bronze strip. The bronzestrip has a thickness of less than about 762 microns. The bronze stripis plated with chromium of a thickness of less than about 3 microns. Ametal alloy having a composition of at least about 45% tin, at leastabout 45% zinc, less than about 1% of a metal additive, and less thanabout 0.1% lead is heated in a melting pot at a temperature of about301-482° C. The bronze strip is passed through the melting pot having alength of about 16 feet at a speed of about 100 ft/min. The bronze striphas a resident time in the melting pot of less than about 10 seconds.The coated bronze strip is passed through coating rollers and/or anair-knife to achieve a coating thickness of about 7-77 microns. Thecoated bronze strip is rewound into a roll of coated bronze strip.

EXAMPLE UU

[0265] A aluminum strip is unwound from a roll of aluminum strip. Thealuminum strip has a thickness of less than about 762 microns. Thealuminum strip is continuously plated with a tin layer of about 1-3microns thick. A metal alloy having a composition of at least about 45%tin and at least about 45% zinc is heated in a melting pot at atemperature of about 301-482° C. The aluminum strip is passed throughthe melting pot having a length of about 16 feet at a speed of about 100ft./min. The aluminum strip has a resident time in the melting pot ofless than about 10 seconds. The coated aluminum strip is passed throughcoating rollers and/or an air-knife to achieve a coating thickness ofabout 7-77 microns. The coated aluminum strip is rewound into a roll ofcoated aluminum strip.

EXAMPLE VV

[0266] A tin strip is unwound from a roll of tin strip and continuouslyplated with a tin layer of a thickness of less than about 3 microns. Thetin strip has a thickness of less than about 762 microns. A metal alloyhaving a composition of at least about 45% tin, at least about 45% zinc,and less than about 0.1% lead is heated in a melting pot at atemperature of about 301-427° C. The tin strip is passed through themelting pot having a length of about 16 feet at a speed of about 100ft/min. The tin has a resident time in the melting pot of less thanabout 10 seconds. The coated tin strip is passed through coating rollersand/or an air-knife to achieve a coating thickness of about 7-77microns. The coated tin strip is rewound into a roll of coated tinstrip.

EXAMPLE WW

[0267] A brass strip is unwound from a roll of brass strip. The brassstrip is continuously plated with a tin layer of about 1-3 micronsthick. The brass strip has a thickness of less than about 762 microns. Ametal alloy having a composition of at least about 20% tin, and at leastabout 75% zinc is heated in a melting pot at a temperature of about301-427° C. The brass strip is passed through the melting pot having alength of about 16 feet at a speed of about 100 μl/min. The brass striphas a resident time in the melting pot of less than about 10 seconds.The coated brass strip is passed through coating rollers and/or anair-knife to achieve a coating thickness of about 7-77 microns. Thecoated brass strip is rewound into a roll of coated brass strip.

EXAMPLE XX

[0268] A brass strip is unwound from a roll of brass strip and ispickled with a hydrochloric acid solution and a copper sulfate solution.Copper is plated onto the brass strip surface during pickling to form acopper layer of about 1-3 microns thick. The brass strip has a thicknessof less than about 762 microns. A metal alloy having a composition of atleast about 70% tin, at least about 25% zinc, and less than about 0.2%lead is heated in a melting pot at a temperature of about 301-482° C.The brass strip is coated by metal strap jets. The coated brass strip ispassed through coating rollers and/or an air-knife to achieve a coatingthickness of about 7-77 microns. The coated brass strip is rewound intoa roll of coated brass strip.

EXAMPLE YY

[0269] A brass strip is unwound from a roll of brass strip and ispickled with a hydrochloric acid solution and chemically activated witha zinc chloride solution prior to coating. The brass strip has athickness of less than about 762 microns. The brass strip is notpre-heated prior to coating. A tin alloy having a composition of about90-99% tin, and less than about 2% lead is heated in a melting pot at atemperature of about 237-246° C. The brass strip is passed through themelting pot at a speed of about 100 ft/min. The brass strip has aresident time in the melting pot of less than about 10 seconds. Thecoated brass strip is passed through coating rollers and/or an air knifeto achieve a coating thickness of about 7-51 microns. The coated brassstrip is then cooled. The coated brass strip is then oxidized to removethe coated tin alloy to expose and pacify the heat created intermetalliclayer. The brass strip is then wound into a roll of brass strip.

EXAMPLE ZZ

[0270] A brass strip is unwound from a roll of brass strip and ispickled with a hydrochloric acid solution and chemically activated witha zinc chloride solution prior to coating. The brass strip has athickness of less than about 762 microns. The brass strip is plated withnickel having a thickness of less than about 3 microns. The brass stripis preheated prior to coating. A tin alloy having a composition of about90-99% tin, and less than about 2% lead is heated in a melting pot at atemperature of about 237-482° C. The brass strip is passed through themelting pot at a speed of about 100 ft/min. The brass strip has aresident time in the melting pot of less than about 10 seconds. Thecoated brass strip is passed through coating rollers and/or an air-knifeto achieve a coating thickness of about 7-51 microns. The coated brassstrip is cooled and then oxidized to remove the tin alloy to expose andpacify the heat created intermetallic layer. The brass strip is thenwound into a roll of brass strip.

EXAMPLE AAA

[0271] A brass strip is unwound from a roll of brass strip. The brassstrip has a thickness of less than about 762 microns. The brass strip ispickled to clean the brass strip surface. The brass strip is notpre-heated prior to coating. A tin alloy having a composition of about99% tin, and less than about 0-5% lead is applied to the brass strip byan electroplating process. The plated brass strip is then flow heatedfor less than about 5 minutes. The coated brass strip is passed throughcoating rollers and/or an air-knife to achieve a coating thickness ofabout 7-51 microns. The coated brass strip is then cooled. The coatedbrass strip is then oxidized to remove the tin alloy and to expose andpacify the heat created intermetallic layer. The brass strip is thenwound into a roll of brass strip.

EXAMPLE BBB

[0272] A brass strip is unwound from a roll of brass strip and platedwith a zinc layer having a thickness of less than about 3 microns. Thebrass strip has a thickness of less than about 762 microns. The brassstrip is pre-heated prior to coating. A tin alloy having a compositionof about 90-99% tin, and less than about 0-1% lead is passed through ametal spaying process at a speed of up to 100 ft/min. The coated brassstrip is then passed through coating rollers and/or an air-knife toachieve a coating thickness of about 7-51 microns. The coated brassstrip is cooled and then oxidized to remove the tin alloy and to exposeand pacify the heat created intermetallic layer. The brass strip is thencut into sheets.

EXAMPLE CCC

[0273] A brass strip is unwound from a roll of brass strip and ispickled with an acid solution and then chemically activated with achemical activation solution. The brass strip is plated with a metallayer of about 1-3 microns thick. The brass strip is not pre-heatedprior to coating. A tin alloy having a composition of about 90-99% tinis plated onto the brass strip and then flow heated. The brass strip isthen coated again by a spray metal process. The coated brass strip isthen passed through coating rollers and/or an air-knife to achieve acoating thickness of about 7-51 microns. The coated brass strip is thencooled and wound into a roll of brass strip. The roll of coated brassstrip is formed into roofing materials and installed on a building. Theformed coated strip is then exposed on site to an oxidizing solution toremove the tin alloy and to expose and to pacify the intermetalliclayer.

EXAMPLE DDD

[0274] A metal alloy is formed into a metal strip to be formed tovarious types of materials, or into a solder or a welding wire forconnecting two or more metal materials together. One general compositionof the metal strip, solder or welding wire is 20-70% tin, 30-75% zinc,0.0005-2% aluminum, 0.001-2% antimony, 0.0001-1% bismuth, 0-2% copper,0-0.5% lead, 0.0001-0.1% titanium. Another formulation of the metalstrip, solder or welding wire is 40-60% tin, 40-60% zinc, 0.0005-0.75%aluminum, 0.001-1% antimony, 0.0001-0.2% bismuth, 0-0.01% arsenic,0-0.01% cadmium, 0-6.01% chromium, 0.001-1% copper, 0-0.1% iron, 0-0.1%lead, 0-0.01% manganese, 0-0.2% nickel, 0-0.01% silver, 0.0005-0.05%titanium. Still another formulation of the metal strip, solder orwelding wire includes 30-70% tin; 30-70% zinc; 0.0001-0.5% aluminum;0.001-2% antimony; 0-0.01% arsenic; 0.0001-1% bismuth; 0-0.01% boron;0-0.01% cadmium; 0-0.05% carbon; 0-0.05% chromium; 0-2% copper; 0-0.1%iron; 0-0.5% lead; 0-0.01% magnesium; 0-0.01% manganese; 0-0.01%molybdenum; 0-1% nickel; 0-0.01% silicon; 0-0.01% silver; 0-0.01%sulfur; 0-0.01% tellurium; 0.0001-0.1% titanium; and 0-0.01% vanadium.Yet another formulation of the metal strip, solder or welding wire is40-60% tin; 40-60% zinc; 0.0005-0.4% aluminum; 0.01-0.8% antimony;0-0.005% arsenic; 0.001-0.05% bismuth; 0-0.005% cadmium; 0.005-0.5%copper; 0-0.05% iron; 0-0.1% lead; 0-0.05% nickel; 0-0.005% silver; and0.0005-0.05% titanium. Still yet a further formulation of the metalstrip, solder or welding wire is 48-52% tin; 48-52% zinc; 0.005-0.24%aluminum; 0.05-0.64% antimony; 0-0.001% arsenic; 0.002-0.005% bismuth;0-0.001% cadmium; 0.01-0.3% copper; 0-0.016% iron; 0-0.08% lead;0-0.001% nickel; 0-0.001% silver; 0.001-0.02% titanium. Anotherformulation of the metal strip, solder or welding wire is 5-70% tin;30-95% zinc; 0-0.25% aluminum; 0-0.02% chromium; 0-1.5% copper; 0-0.01%iron; 0-0.01% lead; 0-0.01% manganese; and 0-0.18% titanium. When themetal alloy is used as a solder metal or electrode, the metal alloy isformed into a thin wire or thin strip by common known processes. Thewire or thin strip is typically rolled for later processing or use. Themetal alloy made for solder typically includes aluminum and/or titaniumsince these two metal additives positively affect the surface tension ofthe metal alloy in the molten state so that the molten metal alloy hasthe desired wetting characteristics. The higher the concentration oftitanium and/or aluminum, the more the solder will bead when applied toa workpiece. The addition of titanium and/or aluminum to the metal alloyalso causes the metal alloy to resist flowing at temperatures near themelting point of the metal alloy. This resistance imparts excellentsoldering characteristics. The titanium and/or aluminum are believed tocause oxide formation on the surface of the molten solder to form a dullgreyish, earth tone colored solder. The titanium and aluminum are alsobelieve to assist in forming an intermetallic layer with the tin andzinc in the metal alloy and the workpiece before solidification of thesolder to thereby form a strong bond with the workpiece. The soldertypically includes little, if any, lead additions, and such, any lead inthe solder is typically due to impurities. The solder composition isparticularly useful in soldering carbon steel, stainless steel, copper,copper alloys, tin, tin metal alloys, zinc and zinc alloys. However, thesolder can be used on other types of metals. If the solder is to be usedto connect copper or copper alloys, copper is typically added to themetal alloy composition. The addition of copper reduces the reactivityof the solder with the copper or copper alloy materials. The solder maybe used with a wide variety of fluxes. If the solder is to be used inultrasonic welding, a flux is typically not used.

EXAMPLE EEE

[0275] The metal alloy is used for standing seam and press fit(mechanical joining such as shown in U.S. Pat. No. 4,987,716)applications for roofing. In standing seam applications, the edges ofthe roofing materials are folded together and then soldered to form awater tight seal. The metal alloy inherently includes excellentsoldering characteristics. When the metal alloy is heated, it has thenecessary wetting properties to produce a tight water resistant seal. Asa result, the metal alloy acts as both a corrosive resistive coating anda soldering agent for standing seam roofing systems. The metal alloycoated can be also welded with standard solders. Typical solders containabout 50% tin and about 50% lead. The metal alloy has the addedadvantage of being able to be soldered with low or no-lead solders. Themetal alloy coated roofing materials also can be used in mechanicallyjoined roofing systems due to the malleability of the metal alloy.Mechanically joined systems form water tight seals by folding adjacentroof material edges together and subsequently applying a compressiveforce to the seam in excess of about 1,000 psi. Under these highpressures, the metal alloy plastically deforms within the seam andproduces a water tight seal.

[0276] The invention has been described with reference to preferred andalternate embodiments. Modifications and alterations will becomeapparent to those skilled in the art upon reading and understanding thedetailed discussion of the invention provided herein. This invention isintended to include all such modifications and alterations insofar asthey come within the scope of the present invention.

We claim:
 1. A method of producing a corrosion-resistant metal stripcomprising the steps of: (a) providing a metal strip from a roll ofstrip; (b) coating said metal strip with a corrosion resistant metalalloy, said corrosion resistant metal alloy comprising tin, zinc and ametal additive, said tin content plus said zinc content constituting amajority of the metal alloy, said metal alloy including at least 15weight percent tin and at least 10 weight percent zinc, said metaladditive including an additive selected from the group consisting of atleast an effective amount of stabilizer to inhibit crystallization ofthe tin in said metal alloy, at least an effective amount of a coloringagent to reduce the reflectivity of the metal alloy, at least aneffective amount of a corrosion-resistant agent to enhance the corrosionresistant properties of the metal alloy, and mixtures thereof.
 2. Themethod as defined in claim 1, including the step of forming a heatcreated intermetallic layer between the surface of said metal strip andsaid metal alloy, said heat created intermetallic layer having athickness of up to about 10 microns.
 3. The method as defined in claim2, including the step of introducing heat to said metal alloy to formsaid heat created intermetallic layer, said step of introducing heatselected from the group consisting of exposing molten metal alloy tosaid metal strip, flow heating said metal alloy, and combinationsthereof.
 4. The method as defined in claim 1, wherein said metal alloycomprises: Tin 15-90 Zinc 10-85 Aluminum 0-2 Antimony 0-2 Bismuth  0-1.7 Copper 0-2 Iron 0-1 Magnesium 0-2 Nickel 0-2 Titanium 0-1


5. The method as defined in claim 4, wherein said metal alloy comprises:Tin 15-90 Zinc 10-85 Aluminum 0-2 Antimony 0-2 Bismuth   0-1.7 Copper0-2 Iron 0-1 Lead   0-0.5 Magnesium 0-2 Nickel 0-2 Titanium 0-1


6. The method as defined in claim 5, wherein said metal alloy comprises:Tin 15-90 Zinc 10-85 Aluminum 0-2 Antimony 0-2 Bismuth   0-1.7 Boron  0-0.01 Cadmium   0-0.1 Carbon   0-0.5 Chromium   0-0.5 Copper 0-2 Iron0-1 Lead   0-0.5 Magnesium   0-0.4 Manganese   0-0.1 Molybdenum   0-0.1Nickel 0-2 Silicon   0-0.5 Titanium 0-1 Vanadium   0-0.1


7. The method as defined in claim 6, wherein said metal alloy comprises:Tin 20-90 Zinc 10-80 Aluminum   0-0.5 Antimony 0-2 Bismuth   0-1.5 Boron  0-0.01 Cadmium   0-0.1 Carbon   0-0.5 Chromium   0-0.5 Copper 0-2 Iron0-1 Lead   0-0.5 Magnesium   0-0.4 Manganese   0-0.1 Molybdenum   0-0.1Nickel 0-1 Silicon   0-0.5 Titanium   0-0.15 Vanadium   0-0.1